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 two of key 8?
Emphasize the connections between processes and full employee participation in improvement making
Industrial engineering methodologies
Anyone could find any file within one minute.
It's hard because it deals with attitudes of employees.


2. What is push production?

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

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4. What is an external setup element?
Can be done while the machine is still processing.
Continuous improvement of person and process
Can only be done when the machine is stopped or shut down.
You have to communicate! Coordinate where the output is going to be stored.


5. What is level four of key 8?
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.
Helps you understand the facts as they are.
It's hard because it deals with attitudes of employees.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method


6. What are the three key technical activities in a TPM program?
Backorders create complacency.
Preventative maintenance - Prevention maintenance - Corrective prevention
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Run the machines into the ground


7. 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.
Hands-on activity based on the facts - not opinion.
There is a shotgun approach to improvements; people have little concern for improving methods.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


8. What is pull production?
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
Knowledge - Job security - Safety - Simplicity
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


9. What is level 5 of key 9?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Everyone recognizes that monitoring is waste
Knowledge - Job security - Safety - Simplicity
Large scale improvement


10. What does TPM do?
Study the movement and motions of a worker or associate
Quick changeover technology
Made the basic elements of human motion (therbligs)
Prevents equipment from breaking down or malfunctioning.


11. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
Anyone could find any file within one minute.
Video tape a person doing this so they can review what they're doing and improve.
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.


12. What is the purpose of video analysis?

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13. What is kaikaku?
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'.
Large scale improvement
You want to equalize your work loads in terms of your lot size - one-piece flow.
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


14. What are the different types of motions required for performing an operation? (Type 1 motions)
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
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Double capacity and the per unit production cost is 60% of the lower capacity option.
One operator handling several machines or processes


15. What is key #8?
Doubling productivity - Productivity = Output / TEE
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Coupled manufacturing
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


16. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Involving production employees in the total machine maintenance process.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Anyone could find any file within one minute.


17. What are the five components of TPM?
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
Prevents equipment from breaking down or malfunctioning.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover


18. What is level 1 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
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Run the machines into the ground


19. What are the 5 pillars of TPM?

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20. What are the three pillars of lean systems?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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.


21. What are the steps in motion study?
Coupled manufacturing
Time measuring
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Made the basic elements of human motion (therbligs)


22. What are the three principles of prevention?
Can only be done when the machine is stopped or shut down.
Inventory waste - Delay - Declining quality
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.


23. What is level five of key 7?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Anyone could find any file within one minute.
Machines work together to prevent overproduction - it stops once it meets demands.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign


24. At level three of key 6 - what is the methodology employees have been trained to use?
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.
Morning pep talk meetings are held everyday
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
Industrial engineering methodologies


25. What is level 2 of key 10?
Morning pep talk meetings are held everyday
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.
Doubling productivity - Productivity = Output / TEE
Workers are conscientious about sticking to the work throughout the designated working areas.


26. What are the process improvement steps?
Maintaining equipment
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
Contamination - inadequate lubrication - misoperation
Can only be done when the machine is stopped or shut down.


27. What is level two of key 6?
Each section does its own thing; each workplace functions independently
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


28. What are the motions that do not perform an operation?
Doubling productivity - Productivity = Output / TEE
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
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)


29. What appears to be the primary metric in key 6?
Time measuring
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.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


30. What is level three of key 6?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
To eliminate the big 3.
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
People have learned how to make systematic improvements at each process.


31. What is level five of key 8?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Maintaining equipment
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 have to communicate! Coordinate where the output is going to be stored.


32. What is the order processing and distribution loops?

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33. What is key #9?
Quick changeover technology
Maintaining equipment
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.
One operator handling several machines or processes


34. What are the benefits of quick changeover for companies?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Prevents equipment from breaking down or malfunctioning.


35. What is level 4 of key 10?
Emphasize the connections between processes and full employee participation in improvement making
Cycle time - work sequence - standard inventory
Identifying problems before they cause breakdowns.
Workers are conscientious about sticking to the work throughout the designated working areas.


36. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
Operators know they must keep their machines in good condition and eliminate the three evils.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
One operator handling several machines or processes


37. What does manufacturing value analysis do?
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
Made the basic elements of human motion (therbligs)
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
All machines can operate during lunch without monitoring and many operators can handle two or more machines


38. What has to be done to get to level two of key 8?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Operators know they must keep their machines in good condition and eliminate the three evils.
You have to communicate! Coordinate where the output is going to be stored.


39. What is preventive maintenance?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Continuous improvement of person and process
To eliminate the big 3.
Operators know they must keep their machines in good condition and eliminate the three evils.


40. What is level 3 of key 10?
Supervisors meet to work out time control issues
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.
Each section does its own thing; each workplace functions independently
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.


41. What is operator flow charting?
Study the movement and motions of a worker or associate
Eliminate certain processes that produce or create waste.
Zero monitor manufacturing
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.


42. What is key #6?
The customer's order starts the process
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.
Manufacturing value analysis
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method


43. What is product flow charting?
Study the flow of a product through the various operations
Identifying problems before they cause breakdowns.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.


44. What is key #7?
Involving production employees in the total machine maintenance process.
Zero monitor manufacturing
Industrial engineering methodologies
Time control and commitment


45. What is corrective maintenance?
Prevents equipment from breaking down or malfunctioning.
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.
You have to communicate! Coordinate where the output is going to be stored.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.


46. What is prevention maintenance?
Manufacturing value analysis
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
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.
Coupled manufacturing


47. What is autonomation (Jidoka)?
Manufacturing value analysis
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Determining the life expectancy of components in order to replace them at the optimum time.
Executives do not understand the high rate of return linked to integrated improvement.


48. What is level five of key 5?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Morning pep talk meetings are held everyday
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Machines work together to prevent overproduction - it stops once it meets demands.


49. What is the 'Six-Tenths Rule'?
Work and break times are left to the workers' discretion
Double capacity and the per unit production cost is 60% of the lower capacity option.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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.


50. What is level one of key 5?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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
Preventative maintenance - Prevention maintenance - Corrective prevention