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 is level five of key 6?
Hands-on activity based on the facts - not opinion.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Doubling productivity - Productivity = Output / TEE
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.


2. What is key #8?
Coupled manufacturing
Zero monitor 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.
Backorders create complacency.


3. What is push production?

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4. What is the goal of motion study?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Manufacturing value analysis
To eliminate the big 3.
No one realizes that monitoring is waste - not work


5. What are the three principles of prevention?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
The available production time divided by the rate of customer demand
Coupled manufacturing


6. What are the benefits of quick changeover for companies?
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
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs


7. What are the five components of TPM?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Preventative maintenance - Prevention maintenance - Corrective prevention
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
Filming someone with a light on their finger so you can see the movements to better improve the design.


8. What is key #5?
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
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Quick changeover technology


9. What is level 5 of key 9?
Made the basic elements of human motion (therbligs)
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


10. What is the 'Six-Tenths Rule'?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Double capacity and the per unit production cost is 60% of the lower capacity option.
Work and break times are left to the workers' discretion
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


11. What is level 3 of key 10?
Supervisors meet to work out time control issues
Made the basic elements of human motion (therbligs)
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.


12. What is the purpose of Chronocyclegraphic analysis?
Prevents equipment from breaking down or malfunctioning.
The available production time divided by the rate of customer demand
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.
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.


13. What are the motions that slow down Type 1 motions?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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)
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Everyone understands the need for PM; PM has been implemented for the most important machines.


14. What is the make/ship loop?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Backorders create complacency.
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.


15. What is level 1 of key 10?

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16. What is level four of key 8?
Everyone understands the need for PM; PM has been implemented for the most important machines.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Large scale improvement
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method


17. What is level two of key 8?
Emphasize the connections between processes and full employee participation in improvement making
Study the flow of a product through the various operations
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
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


18. What is preventative maintenance?
Identifying problems before they cause breakdowns.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Manufacturing value analysis


19. What is preventive maintenance?
Video tape a person doing this so they can review what they're doing and improve.
Workers are conscientious about sticking to the work throughout the designated working areas.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
People have learned how to make systematic improvements at each process.


20. What is the new product introduction loop?

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21. What is level 2 of key 9?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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 controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


22. What is the main goal of MVA?
To eliminate the big 3.
Contamination - inadequate lubrication - misoperation
Doubling productivity - Productivity = Output / TEE
The customer's order starts the process


23. What is the purpose of Cyclegraphic analysis?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
You have to communicate! Coordinate where the output is going to be stored.
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


24. What is level two of key 7?
Everyone recognizes that monitoring is waste
It's hard because it deals with attitudes of employees.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Preventative maintenance - Prevention maintenance - Corrective prevention


25. What is key #6?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Machines work together to prevent overproduction - it stops once it meets demands.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Manufacturing value analysis


26. What is level four of key 7?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Supervisors meet to work out time control issues
You have to communicate! Coordinate where the output is going to be stored.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.


27. What is level three of key 6?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Emphasize the connections between processes and full employee participation in improvement making
People have learned how to make systematic improvements at each process.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence


28. What is kaikaku?
Large scale improvement
Run the machines into the ground
Emphasize the connections between processes and full employee participation in improvement making
Supervisors meet to work out time control issues


29. Full work systems
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
Quick changeover studies begin; some employees are learning how to implement single changeover.
You have to communicate! Coordinate where the output is going to be stored.


30. What is the trouble with large-lot production?
Supervisors meet to work out time control issues
Quick changeover studies begin; some employees are learning how to implement single changeover.
Inventory waste - Delay - Declining quality
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.


31. What is the strategic business development loop?
Supervisors meet to work out time control issues
Executives do not understand the high rate of return linked to integrated improvement.
Study the flow of a product through the various operations
People have learned how to make systematic improvements at each process.


32. What is level five of key 7?
Industrial engineering methodologies
Prevents equipment from breaking down or malfunctioning.
Time it takes to make one unit
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign


33. What are the 6 Big Losses of TPM?
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
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
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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


34. What is the purpose of video analysis?

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35. What are the process improvement steps?
Machines work together to prevent overproduction - it stops once it meets demands.
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
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


36. What is focused improvement?

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37. What is level one of key 8?
Morning pep talk meetings are held everyday
Manufacturing value analysis
Backorders create complacency.
Each section does its own thing; each workplace functions independently


38. What is predictive maintenance?
Determining the life expectancy of components in order to replace them at the optimum time.
Can only be done when the machine is stopped or shut down.
Made the basic elements of human motion (therbligs)
Quick changeover technology


39. What is cycle time?
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.
You have to communicate! Coordinate where the output is going to be stored.
The available production time divided by the rate of customer demand
Time it takes to make one unit


40. What is level four of key 6?
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
Industrial engineering methodologies
Helps you understand the facts as they are.


41. What is key #7?
Zero monitor manufacturing
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.
Industrial engineering methodologies
Each section does its own thing; each workplace functions independently


42. What are the functions and rules of kanban?
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
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
You want to equalize your work loads in terms of your lot size - one-piece flow.
Supervisors meet to work out time control issues


43. What is the purpose of operator flow charting?
Knowledge - Job security - Safety - Simplicity
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Coupled manufacturing
Eliminate certain processes that produce or create waste.


44. What is operator flow charting?
Hands-on activity based on the facts - not opinion.
Study the movement and motions of a worker or associate
Each section does its own thing; each workplace functions independently
Study the flow of a product through the various operations


45. What is the value of TPM?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
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.
Made the basic elements of human motion (therbligs)
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign


46. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Each section does its own thing; each workplace functions independently
Manufacturing value analysis


47. What is multi-process handling?
Operators know they must keep their machines in good condition and eliminate the three evils.
One operator handling several machines or processes
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Double capacity and the per unit production cost is 60% of the lower capacity option.


48. What are the benefits of properly maintaining equipment?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Knowledge - Job security - Safety - Simplicity
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal


49. What is level 5 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.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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
You want to equalize your work loads in terms of your lot size - one-piece flow.


50. What is level one of key 7?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
No one realizes that monitoring is waste - not work
Continuous improvement of person and process
There is a shotgun approach to improvements; people have little concern for improving methods.