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 Chronocyclegraphic analysis?
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.
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
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


2. What is production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Machines work together to prevent overproduction - it stops once it meets demands.
All machines can operate during lunch without monitoring and many operators can handle two or more machines


3. Full work systems
Workers are conscientious about sticking to the work throughout the designated working areas.
The customer's order starts the process
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


4. What is level 4 of key 9?
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
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
There is a shotgun approach to improvements; people have little concern for improving methods.


5. What are the functions and rules of kanban?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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


6. What is key 10?
People have learned how to make systematic improvements at each process.
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
Time control and commitment
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.


7. What is the purpose of Cyclegraphic analysis?
Industrial engineering methodologies
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Filming someone with a light on their finger so you can see the movements to better improve the design.


8. What is level five of key 5?
Time it takes to make one unit
Coupled manufacturing
Everyone understands the need for PM; PM has been implemented for the most important machines.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover


9. What is level five of key 6?
Maintaining equipment
Doubling productivity - Productivity = Output / TEE
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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


10. What is the purpose of video analysis?

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


11. What is level 1 of key 10?

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


12. What is autonomous maintenance?
Staying competitive with yesterday's products is difficult - if not impossible.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Involving production employees in the total machine maintenance process.
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


13. 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
Everyone recognizes that monitoring is waste
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.
Identifying problems before they cause breakdowns.


14. What is autonomation (Jidoka)?
Inventory waste - Delay - Declining quality
Large scale improvement
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


15. What is level two of key 7?
Everyone recognizes that monitoring is waste
Work and break times are left to the workers' discretion
Doubling productivity - Productivity = Output / TEE
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


16. What is pull production?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
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
Quick changeover technology
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


17. What is preventative maintenance?
Identifying problems before they cause breakdowns.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
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


18. What are the basic steps in a traditional changeover?
Study the flow of a product through the various operations
Preventative maintenance - Prevention maintenance - Corrective prevention
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.


19. What is the value of TPM?
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
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Large scale improvement
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.


20. What is single file retrieval?
Anyone could find any file within one minute.
Everyone recognizes that monitoring is waste
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.


21. What is kaikaku?
Continuous improvement of person and process
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Large scale improvement
Supervisors meet to work out time control issues


22. What is level 3 of key 10?
Operators know they must keep their machines in good condition and eliminate the three evils.
Supervisors meet to work out time control issues
Can be done while the machine is still processing.
Time measuring


23. What is level two of key 6?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
People mistakenly think that increasing lot sizes is a good way to reduce changeover 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.
Identifying problems before they cause breakdowns.


24. What is prevention maintenance?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Cycle time - work sequence - standard inventory
To eliminate the big 3.
Industrial engineering methodologies


25. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Machines work together to prevent overproduction - it stops once it meets demands.
Time measuring
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.


26. 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.
Study the movement and motions of a worker or associate
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation


27. What is level 4 of key 10?
Everyone understands the need for PM; PM has been implemented for the most important machines.
No one realizes that monitoring is waste - not work
Workers are conscientious about sticking to the work throughout the designated working areas.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.


28. What is the new product introduction loop?

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


29. What is level three of key 5?
No one realizes that monitoring is waste - not work
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Study the movement and motions of a worker or associate
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.


30. What are the three elements of the standard work sheet?
Cycle time - work sequence - standard inventory
Anyone could find any file within one minute.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)


31. What is level 2 of key 9?
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
Executives do not understand the high rate of return linked to integrated improvement.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Time it takes to make one unit


32. What are the benefits of properly maintaining equipment?
There is a shotgun approach to improvements; people have little concern for improving methods.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.


33. What is product flow charting?
Can only be done when the machine is stopped or shut down.
Time measuring
Study the flow of a product through the various operations
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments


34. What is push production?

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


35. What is level one of key 8?
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
Each section does its own thing; each workplace functions independently
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
Filming someone with a light on their finger so you can see the movements to better improve the design.


36. What appears to be the primary metric in key 6?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Time measuring
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Morning pep talk meetings are held everyday


37. What is operator flow charting?
No one realizes that monitoring is waste - not work
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Study the movement and motions of a worker or associate
Study the flow of a product through the various operations


38. What is corrective maintenance?
Anyone could find any file within one minute.
Everyone recognizes that monitoring is waste
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


39. What is level four of key 5?
Determining the life expectancy of components in order to replace them at the optimum time.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Time control and commitment
Preventative maintenance - Prevention maintenance - Corrective prevention


40. 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)
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Determining the life expectancy of components in order to replace them at the optimum time.


41. What is the purpose of operator flow charting?
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
No one realizes that monitoring is waste - not work
Eliminate certain processes that produce or create waste.
Time measuring


42. 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.
Identifying problems before they cause breakdowns.
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
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


43. What is the make/ship loop?
Backorders create complacency.
Continuous improvement of person and process
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
There is a shotgun approach to improvements; people have little concern for improving methods.


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

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


45. What is level one of key 6?
Coupled manufacturing
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.
The available production time divided by the rate of customer demand
There is a shotgun approach to improvements; people have little concern for improving methods.


46. 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
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.


47. What is an external setup element?
Can be done while the machine is still processing.
Time measuring
The customer's order starts the process
Can only be done when the machine is stopped or shut down.


48. What is the purpose of Therblig analysis?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Helps you understand the facts as they are.
Workers are conscientious about sticking to the work throughout the designated working areas.


49. What are the five components of TPM?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Video tape a person doing this so they can review what they're doing and improve.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Hands-on activity based on the facts - not opinion.


50. What are the three pillars of lean systems?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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
Hands-on activity based on the facts - not opinion.
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.