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Lean Management

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Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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1. What is level two of key 8?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Can only be done when the machine is stopped or shut down.
Emphasize the connections between processes and full employee participation in improvement making

2. What is key #8?
Coupled manufacturing
Filming someone with a light on their finger so you can see the movements to better improve the design.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Involving production employees in the total machine maintenance process.

3. What is an external setup element?
Match production volume to demand volume - Operate at the speed of the slowest machine - Standard intra-process inventories are always maintained - The machines work together to prevent overproduction - or stop or shut down after processing a standa
Can be done while the machine is still processing.
Emphasize the connections between processes and full employee participation in improvement making
Industrial engineering methodologies

4. What are the different types of motions required for performing an operation? (Type 1 motions)
Involving production employees in the total machine maintenance process.
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.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.

5. What is preventive maintenance?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
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
Coupled manufacturing

6. What is level five of key 7?
Eliminate certain processes that produce or create waste.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

7. What is level three of key 8?
No one realizes that monitoring is waste - not work
Factory employees begin setting up inter-process stores
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Study the movement and motions of a worker or associate

8. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Anyone could find any file within one minute.
The customer's order starts the process
There is a shotgun approach to improvements; people have little concern for improving methods.

9. Full work systems
Match production volume to demand volume - Operate at the speed of the slowest machine - Standard intra-process inventories are always maintained - The machines work together to prevent overproduction - or stop or shut down after processing a standa
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
One operator handling several machines or processes
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

10. What is level four of key 6?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
You have to communicate! Coordinate where the output is going to be stored.
Study the flow of a product through the various operations

11. What does kanban do?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
The customer's order starts the process
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Helps you understand the facts as they are.

12. What are the 5 pillars of TPM?

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13. What is level 3 of key 10?
Doubling productivity - Productivity = Output / TEE
Supervisors meet to work out time control issues
Maintain normal conditions - early discovery of abnormalities - and prompt response.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

14. At level three of key 6 - what is the methodology employees have been trained to use?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Manufacturing value analysis
Coupled manufacturing
Industrial engineering methodologies

15. What is multi-process handling?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
One operator handling several machines or processes
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.
Workers are conscientious about sticking to the work throughout the designated working areas.

16. What are the three evils?
Determining the life expectancy of components in order to replace them at the optimum time.
Executives do not understand the high rate of return linked to integrated improvement.
Contamination - inadequate lubrication - misoperation
Time measuring

17. What is the purpose of Therblig analysis?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Helps you understand the facts as they are.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
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

18. What are the three principles of prevention?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Maintain normal conditions - early discovery of abnormalities - and prompt response.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

19. What is level two of key 7?
Everyone recognizes that monitoring is waste
Emphasize the connections between processes and full employee participation in improvement making
Inventory waste - Delay - Declining quality
Everyone understands the need for PM; PM has been implemented for the most important machines.

20. What is the trouble with large-lot production?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Inventory waste - Delay - Declining quality
There is a shotgun approach to improvements; people have little concern for improving methods.
Made the basic elements of human motion (therbligs)

21. What is key 10?
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.
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
No one realizes that monitoring is waste - not work

22. What has to be done to get to level two of key 8?
You have to communicate! Coordinate where the output is going to be stored.
Supervisors meet to work out time control issues
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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.

23. What is key #5?
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'.
Knowledge - Job security - Safety - Simplicity
Quick changeover technology
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

24. What is level four of key 8?
Workers are conscientious about sticking to the work throughout the designated working areas.
Involving production employees in the total machine maintenance process.
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
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

25. What is level three of key 6?
People have learned how to make systematic improvements at each process.
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
The production schedule determines how many products each process will turn out and send to the next process. Pushes them onto the customer whether they're ready for them or not.
Double capacity and the per unit production cost is 60% of the lower capacity option.

26. What is the purpose of flowcharting?
Time it takes to make one unit
Determining the life expectancy of components in order to replace them at the optimum time.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Study the movement and motions of a worker or associate

27. What are the flowcharting rules of construction?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
The production schedule determines how many products each process will turn out and send to the next process. Pushes them onto the customer whether they're ready for them or not.
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.

28. What is the main goal of MVA?
Doubling productivity - Productivity = Output / TEE
Time control and commitment
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Inventory waste - Delay - Declining quality

29. What is the purpose of Chronocyclegraphic analysis?
No one realizes that monitoring is waste - not work
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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Coupled manufacturing

30. What is level 5 of key 9?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
One operator handling several machines or processes

31. What did Frank Gilbreth do?
Eliminate certain processes that produce or create waste.
Made the basic elements of human motion (therbligs)
Video tape a person doing this so they can review what they're doing and improve.
Operators know they must keep their machines in good condition and eliminate the three evils.

32. What is level one of key 7?
Preventative maintenance - Prevention maintenance - Corrective prevention
No one realizes that monitoring is waste - not work
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
There is a shotgun approach to improvements; people have little concern for improving methods.

33. What are the three elements of the standard work sheet?
Cycle time - work sequence - standard inventory
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Operators know they must keep their machines in good condition and eliminate the three evils.
It's hard because it deals with attitudes of employees.

34. What is preventative maintenance?
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.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Identifying problems before they cause breakdowns.

35. What is level five of key 5?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Hands-on activity based on the facts - not opinion.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

36. What is push production?

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37. What does TPM do?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Prevents equipment from breaking down or malfunctioning.
People have learned how to make systematic improvements at each process.

38. What is the framework for the morning meeting - the after lunch meeting - and the end-of-the-day meeting?

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39. What are the functions and rules of kanban?
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.
Cycle time - work sequence - standard inventory
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

40. What is level 4 of key 10?
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
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Staying competitive with yesterday's products is difficult - if not impossible.
Workers are conscientious about sticking to the work throughout the designated working areas.

41. What is takt time?
Coupled manufacturing
Maintaining equipment
The available production time divided by the rate of customer demand
Factory employees begin setting up inter-process stores

42. What is production leveling?
Industrial engineering methodologies
Morning pep talk meetings are held everyday
You want to equalize your work loads in terms of your lot size - one-piece flow.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

43. What is level four of key 5?
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.
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.

44. What is level 2 of key 10?
It's hard because it deals with attitudes of employees.
Helps you understand the facts as they are.
Morning pep talk meetings are held everyday
The production schedule determines how many products each process will turn out and send to the next process. Pushes them onto the customer whether they're ready for them or not.

45. What is level one of key 6?
There is a shotgun approach to improvements; people have little concern for improving methods.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

46. What is autonomous maintenance?
Each section does its own thing; each workplace functions independently
Involving production employees in the total machine maintenance process.
Zero monitor manufacturing
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

47. What is the purpose of video analysis?

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48. What is level four of key 7?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Operators know they must keep their machines in good condition and eliminate the three evils.
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)
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.

49. What is key #9?
Time control and commitment
Maintaining equipment
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Quick changeover technology

50. What is key #6?
Made the basic elements of human motion (therbligs)
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Manufacturing value analysis
Executives do not understand the high rate of return linked to integrated improvement.

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