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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. Full work systems
Everyone recognizes that monitoring is waste
Contamination - inadequate lubrication - misoperation
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
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

2. What are the 6 Big Losses 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.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
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

3. What is level one of key 7?
Involving production employees in the total machine maintenance process.
No one realizes that monitoring is waste - not work
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

4. What is level two of key 5?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Zero monitor manufacturing
Cycle time - work sequence - standard inventory

5. 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
Coupled manufacturing
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
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

6. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
Preventative maintenance - Prevention maintenance - Corrective prevention
Time measuring
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

7. What is level 3 of key 9?
Operators know they must keep their machines in good condition and eliminate the three evils.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Video tape a person doing this so they can review what they're doing and improve.

8. What is the purpose of Chronocyclegraphic analysis?
Anyone could find any file within one minute.
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.
Involving production employees in the total machine maintenance process.
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.

9. What is level three of key 8?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Large scale improvement
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
Factory employees begin setting up inter-process stores

10. What are the benefits of quick changeover for associates?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Operators know they must keep their machines in good condition and eliminate the three evils.
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
Knowledge - Job security - Safety - Simplicity

11. What are the motions that do not perform an operation?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Each section does its own thing; each workplace functions independently

12. What is prevention maintenance?
Anyone could find any file within one minute.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Determining the life expectancy of components in order to replace them at the optimum time.
There is a shotgun approach to improvements; people have little concern for improving methods.

13. What is an external setup element?
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
Can be done while the machine is still processing.
Supervisors meet to work out time control issues
Emphasize the connections between processes and full employee participation in improvement making

14. What is the purpose of video analysis?

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

16. What is level 2 of key 10?
Each section does its own thing; each workplace functions independently
Morning pep talk meetings are held everyday
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Time it takes to make one unit

17. What has to be done to get to 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
You have to communicate! Coordinate where the output is going to be stored.
Run the machines into the ground
Quick changeover technology

18. What are the basic steps in a traditional changeover?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Everyone understands the need for PM; PM has been implemented for the most important machines.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

19. What is level one of key 8?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
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 section does its own thing; each workplace functions independently
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

20. 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
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Determining the life expectancy of components in order to replace them at the optimum time.

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

22. What is level one of key 6?
Anyone could find any file within one minute.
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.
Everyone recognizes that monitoring is waste

23. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Everyone understands the need for PM; PM has been implemented for the most important machines.
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 4 of key 10?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Everyone understands the need for PM; PM has been implemented for the most important machines.
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

25. What are the three elements of the standard work sheet?
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
You want to equalize your work loads in terms of your lot size - one-piece flow.
Cycle time - work sequence - standard inventory
Continuous improvement of person and process

26. What is the main goal of MVA?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Doubling productivity - Productivity = Output / TEE
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

27. What is the strategic business development loop?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Anyone could find any file within one minute.
Executives do not understand the high rate of return linked to integrated improvement.

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

29. What is level four of key 7?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
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.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Coupled manufacturing

30. What is level 2 of key 9?
Work and break times are left to the workers' discretion
Operators know they must keep their machines in good condition and eliminate the three evils.
Everyone recognizes that monitoring is waste
Everyone understands the need for PM; PM has been implemented for the most important machines.

31. What is production leveling?
Can be done while the machine is still processing.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
You want to equalize your work loads in terms of your lot size - one-piece flow.
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.

32. What is kaikaku?
Can be done while the machine is still processing.
Large scale improvement
Everyone understands the need for PM; PM has been implemented for the most important machines.
People have learned how to make systematic improvements at each process.

33. What is level two of key 8?
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.
Emphasize the connections between processes and full employee participation in improvement making
Machines work together to prevent overproduction - it stops once it meets demands.
Operators know they must keep their machines in good condition and eliminate the three evils.

34. What is the make/ship loop?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Backorders create complacency.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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

35. What is multi-process handling?
Anyone could find any file within one minute.
Time it takes to make one unit
Quick changeover technology
One operator handling several machines or processes

36. What is the value of TPM?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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.
Zero monitor manufacturing

37. What are the three evils?
Industrial engineering methodologies
Run the machines into the ground
Contamination - inadequate lubrication - misoperation
Emphasize the connections between processes and full employee participation in improvement making

38. What are the flowcharting rules of construction?
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
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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
The available production time divided by the rate of customer demand

39. What is the purpose of flowcharting?
No one realizes that monitoring is waste - not work
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
One operator handling several machines or processes
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

40. What is key #6?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Manufacturing value analysis
The available production time divided by the rate of customer demand
The customer's order starts the process

41. What is single file retrieval?
Anyone could find any file within one minute.
People have learned how to make systematic improvements at each process.
To eliminate the big 3.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

42. What is the trouble with large-lot production?
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.
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.
Inventory waste - Delay - Declining quality
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

43. What is autonomation (Jidoka)?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Morning pep talk meetings are held everyday
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

44. What is level four of key 5?
Emphasize the connections between processes and full employee participation in improvement making
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
To eliminate the big 3.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

45. What is level one of key 5?
People mistakenly think that increasing lot sizes is a good way to reduce changeover 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
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)
Manufacturing value analysis

46. What is cycle time?
Coupled manufacturing
You want to equalize your work loads in terms of your lot size - one-piece flow.
Time it takes to make one unit
Quick changeover studies begin; some employees are learning how to implement single changeover.

47. What is corrective maintenance?
Coupled manufacturing
Zero monitor manufacturing
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Large scale improvement

48. What is preventive maintenance?
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
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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.

49. What is level five of key 8?
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
Can only be done when the machine is stopped or shut down.
Knowledge - Job security - Safety - Simplicity
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

50. What does manufacturing value analysis do?
The available production time divided by the rate of customer demand
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
Continuous improvement of person and process
Hands-on activity based on the facts - not opinion.