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Lean Management

Instructions:

Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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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 are the 5 pillars of TPM?

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2. What are the three evils?
Contamination - inadequate lubrication - misoperation
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
The customer's order starts the process
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

3. What is the strategic business development loop?
People have learned how to make systematic improvements at each process.
Study the movement and motions of a worker or associate
Executives do not understand the high rate of return linked to integrated improvement.
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.

4. What is level four of key 8?
Doubling productivity - Productivity = Output / TEE
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.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

5. What is an external setup element?
The available production time divided by the rate of customer demand
Doubling productivity - Productivity = Output / TEE
Can be done while the machine is still processing.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

6. 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.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
The available production time divided by the rate of customer demand
Determining the life expectancy of components in order to replace them at the optimum time.

7. What is level five of key 5?
It's hard because it deals with attitudes of employees.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Maintaining equipment

8. What is production leveling?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Staying competitive with yesterday's products is difficult - if not impossible.
You want to equalize your work loads in terms of your lot size - one-piece flow.

9. What are the motions that slow down Type 1 motions?
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)
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
People have learned how to make systematic improvements at each process.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

10. 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
Each section does its own thing; each workplace functions independently
Study the movement and motions of a worker or associate
Coupled manufacturing

11. What is kaizen?
Continuous improvement of person and process
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Double capacity and the per unit production cost is 60% of the lower capacity option.
Can only be done when the machine is stopped or shut down.

12. What are the benefits of quick changeover for companies?
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
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
The available production time divided by the rate of customer demand
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.

13. What are the motions that do not perform an operation?
People have learned how to make systematic improvements at each process.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Hands-on activity based on the facts - not opinion.

14. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
Coupled manufacturing
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

15. 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
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
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Can only be done when the machine is stopped or shut down.

16. What is level 5 of key 9?
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
Preventative maintenance - Prevention maintenance - Corrective prevention
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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

17. What is level one of key 6?
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.
There is a shotgun approach to improvements; people have little concern for improving methods.
One operator handling several machines or processes
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

18. What are the basic steps in a traditional changeover?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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.
Time it takes to make one unit
Everyone recognizes that monitoring is waste

19. What are the benefits of properly maintaining equipment?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Staying competitive with yesterday's products is difficult - if not impossible.
Made the basic elements of human motion (therbligs)
Cycle time - work sequence - standard inventory

20. What is predictive maintenance?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Quick changeover studies begin; some employees are learning how to implement single changeover.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Determining the life expectancy of components in order to replace them at the optimum time.

21. What is level one of key 8?
Helps you understand the facts as they are.
Each section does its own thing; each workplace functions independently
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Emphasize the connections between processes and full employee participation in improvement making

22. What is level two of key 8?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Emphasize the connections between processes and full employee participation in improvement making
Eliminate certain processes that produce or create waste.
Video tape a person doing this so they can review what they're doing and improve.

23. What is takt time?
The available production time divided by the rate of customer demand
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Contamination - inadequate lubrication - misoperation
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

24. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
Hands-on activity based on the facts - not opinion.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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.

25. What is product flow charting?
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
Quick changeover technology
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.
Study the flow of a product through the various operations

26. 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
Involving production employees in the total machine maintenance process.
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
Operators know they must keep their machines in good condition and eliminate the three evils.

27. What is the make/ship loop?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Morning pep talk meetings are held everyday
Backorders create complacency.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

28. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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
Maintaining equipment
To eliminate the big 3.

29. What is level 2 of key 9?
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'.
Cycle time - work sequence - standard inventory
Everyone understands the need for PM; PM has been implemented for the most important machines.
You have to communicate! Coordinate where the output is going to be stored.

30. What is the purpose of video analysis?

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31. What is the purpose of Cyclegraphic analysis?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Work and break times are left to the workers' discretion
Time measuring
Filming someone with a light on their finger so you can see the movements to better improve the design.

32. What are the steps in Shingo's changeover system?
Run the machines into the ground
Contamination - inadequate lubrication - misoperation
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Involving production employees in the total machine maintenance process.

33. What is cycle time?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Time it takes to make one unit
Manufacturing value analysis
Identifying problems before they cause breakdowns.

34. What is level three of key 6?
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.
People have learned how to make systematic improvements at each process.
Identifying problems before they cause breakdowns.
Filming someone with a light on their finger so you can see the movements to better improve the design.

35. What is pull production?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Executives do not understand the high rate of return linked to integrated improvement.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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

36. What is level four of key 5?
Helps you understand the facts as they are.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Zero monitor manufacturing

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

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38. What is key #8?
Industrial engineering methodologies
Coupled manufacturing
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

39. What is level three of key 7?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Industrial engineering methodologies
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
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

40. What appears to be the primary metric in key 6?
Time measuring
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Continuous improvement of person and process
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

41. What is the new product introduction loop?

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42. What does TPM do?
Workers are conscientious about sticking to the work throughout the designated working areas.
The customer's order starts the process
Manufacturing value analysis
Prevents equipment from breaking down or malfunctioning.

43. What is full work system?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Manufacturing value analysis
There is a shotgun approach to improvements; people have little concern for improving methods.
Machines work together to prevent overproduction - it stops once it meets demands.

44. What did Frank Gilbreth do?
No one realizes that monitoring is waste - not work
Industrial engineering methodologies
Made the basic elements of human motion (therbligs)
Executives do not understand the high rate of return linked to integrated improvement.

45. What is level five of key 7?
Industrial engineering methodologies
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.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

46. What has to be done to get to level two of key 8?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Everyone recognizes that monitoring is waste
You have to communicate! Coordinate where the output is going to be stored.
Determining the life expectancy of components in order to replace them at the optimum time.

47. What is level five of key 6?
You have to communicate! Coordinate where the output is going to be stored.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Coupled manufacturing
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

48. What is the purpose of flowcharting?
Can be done while the machine is still processing.
Continuous improvement of person and process
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Supervisors meet to work out time control issues

49. What is the 'Six-Tenths Rule'?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Double capacity and the per unit production cost is 60% of the lower capacity option.
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

50. What is preventative maintenance?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Identifying problems before they cause breakdowns.
Time it takes to make one unit
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

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