Test your basic knowledge |

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 are the steps in Shingo's changeover system?
Time it takes to make one unit
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

2. What is level four of key 8?
The available production time divided by the rate of customer demand
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Work and break times are left to the workers' discretion
Knowledge - Job security - Safety - Simplicity

3. What is the main goal of MVA?
Industrial engineering methodologies
Quick changeover studies begin; some employees are learning how to implement single changeover.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Doubling productivity - Productivity = Output / TEE

4. What is the strategic business development loop?
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
Executives do not understand the high rate of return linked to integrated improvement.
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

5. What is predictive maintenance?
The customer's order starts the process
Determining the life expectancy of components in order to replace them at the optimum time.
Zero monitor manufacturing
Video tape a person doing this so they can review what they're doing and improve.

6. What is takt time?
The available production time divided by the rate of customer demand
Study the flow of a product through the various operations
Large scale improvement
Factory employees begin setting up inter-process stores

7. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Large scale improvement
People have learned how to make systematic improvements at each process.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

8. What is level 3 of key 10?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
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
Supervisors meet to work out time control issues
Operators know they must keep their machines in good condition and eliminate the three evils.

9. What is the purpose of Cyclegraphic analysis?
Manufacturing value analysis
Filming someone with a light on their finger so you can see the movements to better improve the design.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Factory employees begin setting up inter-process stores

10. What is an internal setup element?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Morning pep talk meetings are held everyday
Can only be done when the machine is stopped or shut down.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

11. What are the process improvement steps?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
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
Can only be done when the machine is stopped or shut down.
Workers are conscientious about sticking to the work throughout the designated working areas.

12. What are the basic steps in a traditional changeover?
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
You have to communicate! Coordinate where the output is going to be stored.
Machines work together to prevent overproduction - it stops once it meets demands.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

13. What did Frank Gilbreth do?
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
Made the basic elements of human motion (therbligs)
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
All machines can operate during lunch without monitoring and many operators can handle two or more machines

14. What is the purpose of Therblig analysis?
Helps you understand the facts as they are.
Industrial engineering methodologies
Everyone recognizes that monitoring is waste
Emphasize the connections between processes and full employee participation in improvement making

15. What is level two of key 7?
The available production time divided by the rate of customer demand
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Everyone recognizes that monitoring is waste

16. What is operator flow charting?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Study the movement and motions of a worker or associate

17. What is kaizen?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Involving production employees in the total machine maintenance process.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Continuous improvement of person and process

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

19. What is level four of key 5?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Coupled 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.
Double capacity and the per unit production cost is 60% of the lower capacity option.

20. What is level 2 of key 10?
Morning pep talk meetings are held everyday
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
The customer's order starts the process
Factory employees begin setting up inter-process stores

21. What is level 2 of key 9?
Cycle time - work sequence - standard inventory
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
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.

22. What are the three key technical activities in a TPM program?
Preventative maintenance - Prevention maintenance - Corrective prevention
It's hard because it deals with attitudes of employees.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
The customer's order starts the process

23. 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)
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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 be done while the machine is still processing.

24. 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
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
Determining the life expectancy of components in order to replace them at the optimum time.
Each section does its own thing; each workplace functions independently

25. What is level 3 of key 9?
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
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Operators know they must keep their machines in good condition and eliminate the three evils.

26. At level three of key 6 - what is the methodology employees have been trained to use?
Can be done while the machine is still processing.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
No one realizes that monitoring is waste - not work
Industrial engineering methodologies

27. What is level three of key 8?
Inventory waste - Delay - Declining quality
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Factory employees begin setting up inter-process stores
Everyone understands the need for PM; PM has been implemented for the most important machines.

28. What has to be done to get to level two of key 8?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
You have to communicate! Coordinate where the output is going to be stored.

29. What is preventive maintenance?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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
Made the basic elements of human motion (therbligs)
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

30. What does manufacturing value analysis do?
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
You want to equalize your work loads in terms of your lot size - one-piece flow.
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
Video tape a person doing this so they can review what they're doing and improve.

31. What is level one of key 8?
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.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Each section does its own thing; each workplace functions independently

32. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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
Involving production employees in the total machine maintenance process.

33. What is prevention maintenance?
Supervisors meet to work out time control issues
Workers are conscientious about sticking to the work throughout the designated working areas.
One operator handling several machines or processes
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

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

35. What is kaikaku?
You have to communicate! Coordinate where the output is going to be stored.
Time measuring
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Large scale improvement

36. 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.
Anyone could find any file within one minute.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

37. What is key #9?
Maintaining equipment
Zero monitor manufacturing
No one realizes that monitoring is waste - not work
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

38. What is level one of key 7?
No one realizes that monitoring is waste - not work
You have to communicate! Coordinate where the output is going to be stored.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

39. What is the new product introduction loop?

40. What is single file retrieval?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Knowledge - Job security - Safety - Simplicity
Morning pep talk meetings are held everyday
Anyone could find any file within one minute.

41. What is multi-process handling?
One operator handling several machines or processes
You want to equalize your work loads in terms of your lot size - one-piece flow.
Operators know they must keep their machines in good condition and eliminate the three evils.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

42. What is key #5?
Run the machines into the ground
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Quick changeover technology
Video tape a person doing this so they can review what they're doing and improve.

43. What are the flowcharting rules of construction?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Time control and commitment

44. What is level two of key 8?
It's hard because it deals with attitudes of employees.
Maintaining equipment
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Emphasize the connections between processes and full employee participation in improvement making

45. 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.
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
Zero monitor manufacturing
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

46. What is level three of key 5?
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
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

47. What are the functions and rules of kanban?
Doubling productivity - Productivity = Output / TEE
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
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Study the movement and motions of a worker or associate

48. What is the goal of motion study?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
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.

49. What is product flow charting?
Eliminate certain processes that produce or create waste.
It's hard because it deals with attitudes of employees.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Study the flow of a product through the various operations

50. What is key 10?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Everyone recognizes that monitoring is waste
Preventative maintenance - Prevention maintenance - Corrective prevention
Time control and commitment