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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. What is the purpose of Therblig analysis?
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
Helps you understand the facts as they are.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Identifying problems before they cause breakdowns.

2. What is level 4 of key 9?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Contamination - inadequate lubrication - misoperation
Quick changeover studies begin; some employees are learning how to implement single changeover.

3. What is the trouble with large-lot production?
Can be done while the machine is still processing.
Inventory waste - Delay - Declining quality
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation

4. What are the five components of TPM?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Contamination - inadequate lubrication - misoperation

5. What is level 3 of key 9?
Factory employees begin setting up inter-process stores
Operators know they must keep their machines in good condition and eliminate the three evils.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Backorders create complacency.

6. What are the flowcharting rules of construction?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Backorders create complacency.
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

7. What is level two of key 8?
Emphasize the connections between processes and full employee participation in improvement making
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

8. What are the three key technical activities in a TPM program?
Preventative maintenance - Prevention maintenance - Corrective prevention
Quick changeover studies begin; some employees are learning how to implement single changeover.
To eliminate the big 3.
Can be done while the machine is still processing.

9. What is kaikaku?
Large scale improvement
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
Study the flow of a product through the various operations
Contamination - inadequate lubrication - misoperation

10. What is the main goal of MVA?
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'.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Doubling productivity - Productivity = Output / TEE
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.

11. What are the motions that do not perform an operation?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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.
Backorders create complacency.

12. What is the purpose of video analysis?

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13. What is the value of TPM?
Emphasize the connections between processes and full employee participation in improvement making
Quick changeover technology
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.
Continuous improvement of person and process

14. What is pull production?
Eliminate certain processes that produce or create waste.
Zero monitor manufacturing
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
Helps you understand the facts as they are.

15. What is level four of key 5?
Continuous improvement of person and process
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
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Operators know they must keep their machines in good condition and eliminate the three evils.

16. What are the benefits of properly maintaining equipment?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
People have learned how to make systematic improvements at each process.
Inventory waste - Delay - Declining quality

17. What is full work system?
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
Machines work together to prevent overproduction - it stops once it meets demands.
Executives do not understand the high rate of return linked to integrated improvement.
Anyone could find any file within one minute.

18. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
Can only be done when the machine is stopped or shut down.
Supervisors meet to work out time control issues
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

19. What is level three of key 7?
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.
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
Preventative maintenance - Prevention maintenance - Corrective prevention
Emphasize the connections between processes and full employee participation in improvement making

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

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21. Full work systems
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
Machines work together to prevent overproduction - it stops once it meets demands.
Industrial engineering methodologies
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

22. What is Industrial Engineering?
Doubling productivity - Productivity = Output / TEE
Hands-on activity based on the facts - not opinion.
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)
Staying competitive with yesterday's products is difficult - if not impossible.

23. What is key #9?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Emphasize the connections between processes and full employee participation in improvement making
Maintaining equipment
Preventative maintenance - Prevention maintenance - Corrective prevention

24. What does manufacturing value analysis do?
Cycle time - work sequence - standard inventory
Continuous improvement of person and process
Operators know they must keep their machines in good condition and eliminate the three evils.
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

25. What is preventative maintenance?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Identifying problems before they cause breakdowns.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Run the machines into the ground

26. What is preventive maintenance?
Study the flow of a product through the various operations
Study the movement and motions of a worker or associate
Continuous improvement of person and process
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

27. What is single file retrieval?
You want to equalize your work loads in terms of your lot size - one-piece flow.
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.
You have to communicate! Coordinate where the output is going to be stored.

28. What are the functions and rules of kanban?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
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'.
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
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

29. What are the three evils?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Contamination - inadequate lubrication - misoperation
Time control and commitment
There is a shotgun approach to improvements; people have little concern for improving methods.

30. What is the goal of motion study?
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.
To eliminate the big 3.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

31. What is level one of key 5?
Emphasize the connections between processes and full employee participation in improvement making
Time it takes to make one unit
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

32. What are the benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
Study the movement and motions of a worker or associate
There is a shotgun approach to improvements; people have little concern for improving methods.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

33. What is the strategic business development loop?
Made the basic elements of human motion (therbligs)
Emphasize the connections between processes and full employee participation in improvement making
Everyone understands the need for PM; PM has been implemented for the most important machines.
Executives do not understand the high rate of return linked to integrated improvement.

34. What is level 4 of key 10?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Doubling productivity - Productivity = Output / TEE
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'.
Workers are conscientious about sticking to the work throughout the designated working areas.

35. What is autonomation (Jidoka)?
You want to equalize your work loads in terms of your lot size - one-piece flow.
You have to communicate! Coordinate where the output is going to be stored.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Continuous improvement of person and process

36. What is level 3 of key 10?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
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
Supervisors meet to work out time control issues
Staying competitive with yesterday's products is difficult - if not impossible.

37. What is the purpose of operator flow charting?
Eliminate certain processes that produce or create waste.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Anyone could find any file within one minute.

38. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
Double capacity and the per unit production cost is 60% of the lower capacity option.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

39. What are the basic steps in a traditional changeover?
Cycle time - work sequence - standard inventory
Determining the life expectancy of components in order to replace them at the optimum time.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

40. 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.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
People have learned how to make systematic improvements at each process.
Quick changeover studies begin; some employees are learning how to implement single changeover.

41. What is push production?

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42. What is key #7?
Zero monitor manufacturing
Made the basic elements of human motion (therbligs)
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.

43. What are the different types of motions required for performing an operation? (Type 1 motions)
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.
Cycle time - work sequence - standard inventory
Knowledge - Job security - Safety - Simplicity
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

44. What is level 2 of key 9?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Staying competitive with yesterday's products is difficult - if not impossible.
Run the machines into the ground
Everyone understands the need for PM; PM has been implemented for the most important machines.

45. What is operator flow charting?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Study the movement and motions of a worker or associate
Determining the life expectancy of components in order to replace them at the optimum time.
Coupled manufacturing

46. What is the new product introduction loop?

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47. What is prevention maintenance?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
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
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

48. What is level one of key 8?
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
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Workers are conscientious about sticking to the work throughout the designated working areas.
Each section does its own thing; each workplace functions independently

49. What is key 10?
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.
Maintaining equipment
Double capacity and the per unit production cost is 60% of the lower capacity option.
Time control and commitment

50. What is the purpose of Cyclegraphic analysis?
Filming someone with a light on their finger so you can see the movements to better improve the design.
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
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
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.