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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 are the benefits of properly maintaining equipment?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
To eliminate the big 3.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Contamination - inadequate lubrication - misoperation

2. What are the three key technical activities in a TPM program?
Preventative maintenance - Prevention maintenance - Corrective prevention
Everyone understands the need for PM; PM has been implemented for the most important machines.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Doubling productivity - Productivity = Output / TEE

3. What is level three of key 5?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

4. What is kaikaku?
Can be done while the machine is still processing.
Large scale improvement
Study the movement and motions of a worker or associate
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

5. What is an external setup element?
Double capacity and the per unit production cost is 60% of the lower capacity option.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Hands-on activity based on the facts - not opinion.
Can be done while the machine is still processing.

6. What is key 10?
Prevents equipment from breaking down or malfunctioning.
Study the flow of a product through the various operations
Made the basic elements of human motion (therbligs)
Time control and commitment

7. What is key #9?
Maintaining equipment
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
Staying competitive with yesterday's products is difficult - if not impossible.

8. What is the main goal of MVA?
Large scale improvement
Can be done while the machine is still processing.
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'.
Doubling productivity - Productivity = Output / TEE

9. What is multi-process handling?
Executives do not understand the high rate of return linked to integrated improvement.
Time measuring
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
One operator handling several machines or processes

10. What is level five of key 5?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

11. What is level one of key 7?
No one realizes that monitoring is waste - not work
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Time control and commitment

12. What has to be done to get to level two of key 8?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
You have to communicate! Coordinate where the output is going to be stored.
Large scale improvement
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

13. What did Frank Gilbreth do?
Made the basic elements of human motion (therbligs)
Each section does its own thing; each workplace functions independently
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Video tape a person doing this so they can review what they're doing and improve.

14. What is key #8?
Workers are conscientious about sticking to the work throughout the designated working areas.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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
Coupled manufacturing

15. What are the three pillars of lean systems?
No one realizes that monitoring is waste - not work
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
There is a shotgun approach to improvements; people have little concern for improving methods.
You want to equalize your work loads in terms of your lot size - one-piece flow.

16. What are the motions that do not perform an operation?
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
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
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
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

17. What is level five of key 6?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
You have to communicate! Coordinate where the output is going to be stored.
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
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

18. What is an internal setup element?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Can only be done when the machine is stopped or shut down.
It's hard because it deals with attitudes of employees.
Involving production employees in the total machine maintenance process.

19. What is level 2 of key 10?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Preventative maintenance - Prevention maintenance - Corrective prevention
Morning pep talk meetings are held everyday
Continuous improvement of person and process

20. What is level 3 of key 9?
Prevents equipment from breaking down or malfunctioning.
Operators know they must keep their machines in good condition and eliminate the three evils.
Zero monitor manufacturing
It's hard because it deals with attitudes of employees.

21. What is the value of TPM?
You have to communicate! Coordinate where the output is going to be stored.
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.
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.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

22. What are the motions that slow down Type 1 motions?
The available production time divided by the rate of customer demand
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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
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)

23. What is level two of key 6?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Helps you understand the facts as they are.
Study the flow of a product through the various operations
Staying competitive with yesterday's products is difficult - if not impossible.

24. What are the five components of TPM?
Study the flow of a product through the various operations
It's hard because it deals with attitudes of employees.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

25. What are the basic steps in a traditional changeover?
Large scale improvement
Quick changeover technology
Executives do not understand the high rate of return linked to integrated improvement.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

26. What is the make/ship loop?
Backorders create complacency.
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'.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Supervisors meet to work out time control issues

27. What is level three of key 6?
People have learned how to make systematic improvements at each process.
Operators know they must keep their machines in good condition and eliminate the three evils.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
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

28. What is the purpose of operator flow charting?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Eliminate certain processes that produce or create waste.

29. What is key #7?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Zero monitor manufacturing
Everyone understands the need for PM; PM has been implemented for the most important machines.

30. Full work systems
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Can be done while the machine is still processing.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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

31. What are the benefits of quick changeover for companies?
Morning pep talk meetings are held everyday
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
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
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

32. What is prevention maintenance?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Can only be done when the machine is stopped or shut down.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Time it takes to make one unit

33. What are the steps in motion study?
Maintaining equipment
Can only be done when the machine is stopped or shut down.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
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.

34. What is full work system?
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
Backorders create complacency.
Helps you understand the facts as they are.
Machines work together to prevent overproduction - it stops once it meets demands.

35. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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

36. What are the process improvement steps?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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
Cycle time - work sequence - standard inventory
One operator handling several machines or processes

37. What is the 'Six-Tenths Rule'?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
To eliminate the big 3.
Double capacity and the per unit production cost is 60% of the lower capacity option.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

38. What does kanban do?
Quick changeover studies begin; some employees are learning how to implement single changeover.
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 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.

39. What are the 6 Big Losses of TPM?
Can only be done when the machine is stopped or shut down.
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
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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

40. What is key #5?
Quick changeover technology
Cycle time - work sequence - standard inventory
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Time it takes to make one unit

41. What is the new product introduction loop?

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42. What are the three principles of prevention?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Video tape a person doing this so they can review what they're doing and improve.
Eliminate certain processes that produce or create waste.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

43. What is level four of key 5?
Time it takes to make one unit
To eliminate the big 3.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

44. What are the three elements of the standard work sheet?
Run the machines into the ground
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Cycle time - work sequence - standard inventory
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

45. What is level 5 of key 10?
Involving production employees in the total machine maintenance process.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
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
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

46. What is takt time?
Supervisors meet to work out time control issues
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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
The available production time divided by the rate of customer demand

47. What is operator flow charting?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Study the movement and motions of a worker or associate
Doubling productivity - Productivity = Output / TEE
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

48. What is the strategic business development loop?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Involving production employees in the total machine maintenance process.
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
Executives do not understand the high rate of return linked to integrated improvement.

49. What are the 5 pillars of TPM?

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50. What is the purpose of video analysis?

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