Lean Management

Instructions:

• Answer 50 questions in 15 minutes.
• If you are not ready to take this test, you can study here.
• Match each statement with the correct term.
• Don't refresh. All questions and answers are randomly picked and ordered every time you load a test.

This is a study tool. The 3 wrong answers for each question are randomly chosen from answers to other questions. So, you might find at times the answers obvious, but you will see it re-enforces your understanding as you take the test each time.

1. What has to be done to get to level two of key 8?
Emphasize the connections between processes and full employee participation in improvement making
Involving production employees in the total machine maintenance process.
An approach that seeks to fully establish the conditions needed to prevent breakdowns. This approach starts by asking 'why?' repeatedly to discover root causes of breakdowns so that problems can be fixed at the source.
You have to communicate! Coordinate where the output is going to be stored.


2. What does kanban do?
Time measuring
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Video tape a person doing this so they can review what they're doing and improve.


3. What is the purpose of flowcharting?
It analyzes the functions of individual manufacturing steps or motions and analyzes whether they add value to the product - Look at every step in your process and see if it adds value or not. If the answer is yes - can we improve it? If the answer i
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method


4. What are the steps in Shingo's changeover system?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
An approach that seeks to fully establish the conditions needed to prevent breakdowns. This approach starts by asking 'why?' repeatedly to discover root causes of breakdowns so that problems can be fixed at the source.
The available production time divided by the rate of customer demand
Knowledge - Job security - Safety - Simplicity


5. What does manufacturing value analysis do?
It analyzes the functions of individual manufacturing steps or motions and analyzes whether they add value to the product - Look at every step in your process and see if it adds value or not. If the answer is yes - can we improve it? If the answer i
Determining the life expectancy of components in order to replace them at the optimum time.
Helps you understand the facts as they are.
Manufacturing value analysis


6. What is the goal of motion study?
Determining the life expectancy of components in order to replace them at the optimum time.
It analyzes the functions of individual manufacturing steps or motions and analyzes whether they add value to the product - Look at every step in your process and see if it adds value or not. If the answer is yes - can we improve it? If the answer i
To eliminate the big 3.
Filming someone with a light on their finger so you can see the movements to better improve the design.


7. What is production leveling?
To eliminate the big 3.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Determining the life expectancy of components in order to replace them at the optimum time.


8. What is cycle time?
Time it takes to make one unit
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Quick changeover technology
Encourage the workers and get people ready to start working. To review what was done that day and get prepared for the next day's activities and goals.


9. What is prevention maintenance?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
An approach that seeks to fully establish the conditions needed to prevent breakdowns. This approach starts by asking 'why?' repeatedly to discover root causes of breakdowns so that problems can be fixed at the source.
It analyzes the functions of individual manufacturing steps or motions and analyzes whether they add value to the product - Look at every step in your process and see if it adds value or not. If the answer is yes - can we improve it? If the answer i
Study the movement and motions of a worker or associate


10. What is the purpose of Chronocyclegraphic analysis?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Filming someone with a light on their finger that blinks at a pre-determined interval so you can see the movements to better improve the design.
Backorders create complacency.


11. What is level three of key 7?
Each section does its own thing; each workplace functions independently
At least 10% of the projects have succeeded in establishing unmonitored one-cycle operation during the lunch break; at least 10% of office operations have one-page standards
Large scale improvement
Maintain normal conditions - early discovery of abnormalities - and prompt response.


12. What is the value of TPM?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
There is a shotgun approach to improvements; people have little concern for improving methods.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
It generates a payoff that covers the capital and human investment. The benefits of TPM can only be estimated but - nevertheless - should be based on life-cycle costing.


13. What is push production?

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14. What is level 2 of key 9?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
1. Improvement activities are designed to increase equipment effectiveness by eliminating the '6 Big Losses' - 2. An autonomous maintenance program to be performed by equipment operators - 3. A planned maintenance system - 4. Training to improve the
Everyone understands the need for PM; PM has been implemented for the most important machines.
Identifying problems before they cause breakdowns.


15. What are the 6 Big Losses of TPM?
Cycle time - work sequence - standard inventory
1. Breakdown losses (function loss and function reduction) 2. Changeover losses 3. Idling and minor stoppage losses 4. Quality defects and rework (special cause and common cause) 5. Reduced speed losses 6. Start-up/yield losses
Contamination - inadequate lubrication - misoperation
Continuous improvement of person and process


16. What is the warning Kobayashi gives with respect to Key 10?

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17. What are the motions that slow down Type 1 motions?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
They are the result of poor arrangement - timing - and/or work methods. Are all cost and should be eliminated or reduced. (Search - find - select - proposition - hold)
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


18. What is level four of key 6?
Zero monitor manufacturing
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Can only be done when the machine is stopped or shut down.
Run the machines into the ground


19. What is the new product introduction loop?

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20. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Everyone recognizes that monitoring is waste
Emphasize the connections between processes and full employee participation in improvement making


21. What is an internal setup element?
Workers are conscientious about sticking to the work throughout the designated working areas.
Encourage the workers and get people ready to start working. To review what was done that day and get prepared for the next day's activities and goals.
Can only be done when the machine is stopped or shut down.
Manufacturing value analysis


22. What is focused improvement?

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23. What is level two of key 8?
Emphasize the connections between processes and full employee participation in improvement making
The customer's order starts the process
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Maintaining equipment


24. What is level five of key 8?
Made the basic elements of human motion (therbligs)
Identifying and repairing equipment problems before they cause breakdowns. Create a maintenance log for every machines. Then determine which machines are most important and in most need of PM and label these machines as 'Designated PM Equipment'.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
To eliminate the big 3.


25. What are the benefits of properly maintaining equipment?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Contamination - inadequate lubrication - misoperation
Maintaining equipment


26. What are the benefits of quick changeover for companies?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Machines work together to prevent overproduction - it stops once it meets demands.
It's hard because it deals with attitudes of employees.


27. What is the trouble with large-lot production?
It's hard because it deals with attitudes of employees.
Quick changeover technology
Inventory waste - Delay - Declining quality
Determining the life expectancy of components in order to replace them at the optimum time.


28. What is level four of key 8?
Staying competitive with yesterday's products is difficult - if not impossible.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Operators know they must keep their machines in good condition and eliminate the three evils.


29. What is single file retrieval?
Anyone could find any file within one minute.
Preventative maintenance - Prevention maintenance - Corrective prevention
Doubling productivity - Productivity = Output / TEE
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.


30. What are the different types of motions required for performing an operation? (Type 1 motions)
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Maintain normal conditions - early discovery of abnormalities - and prompt response.
It provides pickup or transfer information - Provides production information - Prevents overproduction and excessive transport - Serves as a work order attached to the goods - Prevents defective products by identifying the process making the defectiv
Anyone could find any file within one minute.


31. What is level two of key 6?
Industrial engineering methodologies
Cycle time - work sequence - standard inventory
Discovery is initiated by dissatisfaction - What needs to be improved? (PQCDSM checklist) - Analysis of current conditions - Identify major problem points - Create improvement plan - PDCA - Follow up/ Anchor Change
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.


32. What is full work system?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Everyone recognizes that monitoring is waste
Machines work together to prevent overproduction - it stops once it meets demands.
Cycle time - work sequence - standard inventory


33. What is level 4 of key 9?
Knowledge - Job security - Safety - Simplicity
Machines work together to prevent overproduction - it stops once it meets demands.
Large scale improvement
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal


34. What is level five of key 5?
Run the machines into the ground
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Discovery is initiated by dissatisfaction - What needs to be improved? (PQCDSM checklist) - Analysis of current conditions - Identify major problem points - Create improvement plan - PDCA - Follow up/ Anchor Change
Work and break times are left to the workers' discretion


35. What is kaizen?
Eliminate certain processes that produce or create waste.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Continuous improvement of person and process


36. What is level four of key 7?
Emphasize the connections between processes and full employee participation in improvement making
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Preventative maintenance - Prevention maintenance - Corrective prevention


37. What is level 3 of key 10?
Each process must provide quality products in the desired amounts to their store so their next process customer can get exactly what is needed next. Taking from you what I need and the stocker replenishes it: shopping - Far less WIP here than with pu
Supervisors meet to work out time control issues
Identifying and repairing equipment problems before they cause breakdowns. Create a maintenance log for every machines. Then determine which machines are most important and in most need of PM and label these machines as 'Designated PM Equipment'.
Everyone recognizes that monitoring is waste


38. What are the basic steps in a traditional changeover?
Machines work together to prevent overproduction - it stops once it meets demands.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.


39. What is level 4 of key 10?
1. Improvement activities are designed to increase equipment effectiveness by eliminating the '6 Big Losses' - 2. An autonomous maintenance program to be performed by equipment operators - 3. A planned maintenance system - 4. Training to improve the
Study the flow of a product through the various operations
Workers are conscientious about sticking to the work throughout the designated working areas.
The customer's order starts the process


40. At level three of key 6 - what is the methodology employees have been trained to use?
Everyone recognizes that monitoring is waste
Can only be done when the machine is stopped or shut down.
Industrial engineering methodologies
Cycle time - work sequence - standard inventory


41. What are the three principles of prevention?
It provides pickup or transfer information - Provides production information - Prevents overproduction and excessive transport - Serves as a work order attached to the goods - Prevents defective products by identifying the process making the defectiv
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
You have to communicate! Coordinate where the output is going to be stored.


42. What is level one of key 8?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Each section does its own thing; each workplace functions independently
Workers are conscientious about sticking to the work throughout the designated working areas.
1. Breakdown losses (function loss and function reduction) 2. Changeover losses 3. Idling and minor stoppage losses 4. Quality defects and rework (special cause and common cause) 5. Reduced speed losses 6. Start-up/yield losses


43. What is the 'Six-Tenths Rule'?
Large scale improvement
Double capacity and the per unit production cost is 60% of the lower capacity option.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Executives do not understand the high rate of return linked to integrated improvement.


44. What is level four of key 5?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
They are the result of poor arrangement - timing - and/or work methods. Are all cost and should be eliminated or reduced. (Search - find - select - proposition - hold)
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Identifying and repairing equipment problems before they cause breakdowns. Create a maintenance log for every machines. Then determine which machines are most important and in most need of PM and label these machines as 'Designated PM Equipment'.


45. What are the three key technical activities in a TPM program?
Preventative maintenance - Prevention maintenance - Corrective prevention
One operator handling several machines or processes
Time control and commitment
Machines work together to prevent overproduction - it stops once it meets demands.


46. What are the benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
They are the result of poor arrangement - timing - and/or work methods. Are all cost and should be eliminated or reduced. (Search - find - select - proposition - hold)
Workers are conscientious about sticking to the work throughout the designated working areas.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments


47. What are the functions and rules of kanban?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
It provides pickup or transfer information - Provides production information - Prevents overproduction and excessive transport - Serves as a work order attached to the goods - Prevents defective products by identifying the process making the defectiv
Everyone recognizes that monitoring is waste


48. What is level 1 of key 10?

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49. What is key 10?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Time control and commitment
Factory employees begin setting up inter-process stores


50. What is autonomous maintenance?
Can only be done when the machine is stopped or shut down.
Involving production employees in the total machine maintenance process.
An approach that seeks to fully establish the conditions needed to prevent breakdowns. This approach starts by asking 'why?' repeatedly to discover root causes of breakdowns so that problems can be fixed at the source.
Knowledge - Job security - Safety - Simplicity