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?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Time control and commitment
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'.
You have to communicate! Coordinate where the output is going to be stored.


2. What is key 10?
Time control and commitment
The available production time divided by the rate of customer demand
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.
Everyone understands the need for PM; PM has been implemented for the most important machines.


3. What is single file retrieval?
Large scale improvement
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
Backorders create complacency.
Anyone could find any file within one minute.


4. Full work systems
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


5. What is level 1 of key 10?

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6. What is level two of key 6?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Video tape a person doing this so they can review what they're doing and improve.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover


7. What is multi-process handling?
One operator handling several machines or processes
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Study the movement and motions of a worker or associate
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


8. What are the benefits of properly maintaining equipment?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Executives do not understand the high rate of return linked to integrated improvement.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs


9. What is the purpose of Chronocyclegraphic analysis?
Can be done while the machine is still processing.
Coupled manufacturing
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.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)


10. What are the five components of TPM?
Time it takes to make one unit
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.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance


11. What is level one of key 6?
There is a shotgun approach to improvements; people have little concern for improving methods.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Operators know they must keep their machines in good condition and eliminate the three evils.


12. What is the value of TPM?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Staying competitive with yesterday's products is difficult - if not impossible.
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 level one of key 7?
Study the flow of a product through the various operations
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
No one realizes that monitoring is waste - not work


14. What is level 2 of key 10?
Morning pep talk meetings are held everyday
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Knowledge - Job security - Safety - Simplicity
Workers are conscientious about sticking to the work throughout the designated working areas.


15. What does manufacturing value analysis do?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
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
Quick changeover technology
People have learned how to make systematic improvements at each process.


16. What is an external setup element?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Industrial engineering methodologies
Staying competitive with yesterday's products is difficult - if not impossible.
Can be done while the machine is still processing.


17. What is level five of key 8?
Prevents equipment from breaking down or malfunctioning.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.


18. What appears to be the primary metric in key 6?
Time measuring
Double capacity and the per unit production cost is 60% of the lower capacity option.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Contamination - inadequate lubrication - misoperation


19. What is kaikaku?
Industrial engineering methodologies
Preventative maintenance - Prevention maintenance - Corrective prevention
Large scale improvement
Work and break times are left to the workers' discretion


20. What are the first two steps in setting up a maintenance management system?

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21. What is corrective maintenance?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Time it takes to make one unit


22. What is the purpose of operator flow charting?
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
Can only be done when the machine is stopped or shut down.
Eliminate certain processes that produce or create waste.
Run the machines into the ground


23. What is kaizen?
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.
Time control and commitment
Continuous improvement of person and process
Anyone could find any file within one minute.


24. What is prevention maintenance?
Helps you understand the facts as they are.
Maintaining equipment
Knowledge - Job security - Safety - Simplicity
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


25. What is level 3 of key 10?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
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
Supervisors meet to work out time control issues
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)


26. What are the process improvement steps?
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
No one realizes that monitoring is waste - not work
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Manufacturing value analysis


27. What is the goal of motion study?
To eliminate the big 3.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
The customer's order starts the process


28. What is autonomation (Jidoka)?
Time control and commitment
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
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.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal


29. What are the benefits of quick changeover for companies?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Quick changeover studies begin; some employees are learning how to implement single changeover.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


30. What are the motions that do not perform an operation?
To eliminate the big 3.
Made the basic elements of human motion (therbligs)
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)


31. What are the three principles of prevention?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Continuous improvement of person and process


32. What is level 2 of key 9?
Everyone understands the need for PM; PM has been implemented for the most important machines.
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
Manufacturing value analysis


33. What does TPM do?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Prevents equipment from breaking down or malfunctioning.
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
Eliminate certain processes that produce or create waste.


34. What are the functions and rules of kanban?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
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
Prevents equipment from breaking down or malfunctioning.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.


35. What is the 'Six-Tenths Rule'?
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.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Double capacity and the per unit production cost is 60% of the lower capacity option.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover


36. 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
Can be done while the machine is still processing.
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
Study the movement and motions of a worker or associate


37. What is the main goal of MVA?
Doubling productivity - Productivity = Output / TEE
Contamination - inadequate lubrication - misoperation
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs


38. What are the three evils?
Contamination - inadequate lubrication - misoperation
Made the basic elements of human motion (therbligs)
Coupled manufacturing
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


39. What is the purpose of video analysis?

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40. What is the order processing and distribution loops?

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41. What is level five of key 6?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Large scale improvement


42. What is cycle time?
Time it takes to make one unit
Everyone understands the need for PM; PM has been implemented for the most important machines.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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


43. What is level three of key 5?
Run the machines into the ground
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Everyone recognizes that monitoring is waste


44. What is level one of key 5?
Prevents equipment from breaking down or malfunctioning.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


45. What is level four of key 5?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


46. What is preventive maintenance?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Executives do not understand the high rate of return linked to integrated improvement.
Factory employees begin setting up inter-process stores
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


47. What is push production?

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


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

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50. What are the three pillars of lean systems?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Everyone understands the need for PM; PM has been implemented for the most important machines.