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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. At level three of key 6 - what is the methodology employees have been trained to use?
It's hard because it deals with attitudes of employees.
Video tape a person doing this so they can review what they're doing and improve.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Industrial engineering methodologies

2. What is level four of key 6?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

3. What are the five components of TPM?
Quick changeover technology
There is a shotgun approach to improvements; people have little concern for improving methods.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Contamination - inadequate lubrication - misoperation

4. What is production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Everyone recognizes that monitoring is waste
Workers are conscientious about sticking to the work throughout the designated working areas.

5. What is the main goal of MVA?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Inventory waste - Delay - Declining quality
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)
Doubling productivity - Productivity = Output / TEE

6. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Factory employees begin setting up inter-process stores
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

7. What is an external setup element?
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
One operator handling several machines or processes
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

8. What are the benefits of properly maintaining equipment?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
It's hard because it deals with attitudes of employees.
Large scale improvement
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.

9. What did Frank Gilbreth do?
Preventative maintenance - Prevention maintenance - Corrective prevention
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
The customer's order starts the process
Made the basic elements of human motion (therbligs)

10. What is level 2 of key 10?
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
Morning pep talk meetings are held everyday
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)
Anyone could find any file within one minute.

11. What is autonomation (Jidoka)?
Emphasize the connections between processes and full employee participation in improvement making
Eliminate certain processes that produce or create waste.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Manufacturing value analysis

12. What is level one of key 5?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Quick changeover technology
Inventory waste - Delay - Declining quality
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

13. What is level 2 of key 9?
Everyone understands the need for PM; PM has been implemented for the most important machines.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Emphasize the connections between processes and full employee participation in improvement making
Preventative maintenance - Prevention maintenance - Corrective prevention

14. What is key #6?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Manufacturing value analysis
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Can only be done when the machine is stopped or shut down.

15. What does manufacturing value analysis 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
Video tape a person doing this so they can review what they're doing and improve.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Knowledge - Job security - Safety - Simplicity

16. What are the basic steps in a traditional changeover?
Double capacity and the per unit production cost is 60% of the lower capacity option.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Machines work together to prevent overproduction - it stops once it meets demands.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

17. 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.
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
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
All machines can operate during lunch without monitoring and many operators can handle two or more machines

18. What is key #8?
Coupled manufacturing
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Emphasize the connections between processes and full employee participation in improvement making
Backorders create complacency.

19. What is preventive maintenance?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Maintaining equipment
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Coupled manufacturing

20. What is level four of key 5?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

21. What is single file retrieval?
Anyone could find any file within one minute.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
You have to communicate! Coordinate where the output is going to be stored.
Morning pep talk meetings are held everyday

22. What is the order processing and distribution loops?

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23. What is level 3 of key 9?
Eliminate certain processes that produce or create waste.
Operators know they must keep their machines in good condition and eliminate the three evils.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
All machines can operate during lunch without monitoring and many operators can handle two or more machines

24. What is level 4 of key 10?
Workers are conscientious about sticking to the work throughout the designated working areas.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Morning pep talk meetings are held everyday
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

25. What is level three of key 6?
Filming someone with a light on their finger so you can see the movements to better improve the design.
People have learned how to make systematic improvements at each process.
Everyone recognizes that monitoring is waste
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

26. What are the first two steps in setting up a maintenance management system?

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27. What are the three key technical activities in a TPM program?
Preventative maintenance - Prevention maintenance - Corrective prevention
Study the movement and motions of a worker or associate
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

28. What is focused improvement?

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29. What are the three evils?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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.
Contamination - inadequate lubrication - misoperation
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

30. What is the 'Six-Tenths Rule'?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Involving production employees in the total machine maintenance process.
There is a shotgun approach to improvements; people have little concern for improving methods.
Double capacity and the per unit production cost is 60% of the lower capacity option.

31. What are the three elements of the standard work sheet?
Cycle time - work sequence - standard inventory
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
Supervisors meet to work out time control issues
Morning pep talk meetings are held everyday

32. What is level two 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
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Emphasize the connections between processes and full employee participation in improvement making
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

33. What is level one of key 6?
There is a shotgun approach to improvements; people have little concern for improving methods.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Can be done while the machine is still processing.
Can only be done when the machine is stopped or shut down.

34. What is preventative maintenance?
Morning pep talk meetings are held everyday
Identifying problems before they cause breakdowns.
Each section does its own thing; each workplace functions independently
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.

35. What is level 3 of key 10?
Determining the life expectancy of components in order to replace them at the optimum time.
Supervisors meet to work out time control issues
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

36. What is cycle time?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Time it takes to make one unit
Study the flow of a product through the various operations
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

37. What is level one of key 7?
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
No one realizes that monitoring is waste - not work
Can only be done when the machine is stopped or shut down.
Knowledge - Job security - Safety - Simplicity

38. What is full work system?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Machines work together to prevent overproduction - it stops once it meets demands.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
There is a shotgun approach to improvements; people have little concern for improving methods.

39. What are the steps in Shingo's changeover system?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Continuous improvement of person and process
Made the basic elements of human motion (therbligs)
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.

40. What are the three pillars of lean systems?
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.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Industrial engineering methodologies
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

41. What is kaizen?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
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
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Continuous improvement of person and process

42. What is level three of key 5?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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)
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
It's hard because it deals with attitudes of employees.

43. What is an internal setup element?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Can only be done when the machine is stopped or shut down.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Time control and commitment

44. What is predictive maintenance?
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
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.
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'.
Determining the life expectancy of components in order to replace them at the optimum time.

45. What are the steps in motion study?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Run the machines into the ground

46. What is level five of key 6?
Study the flow of a product through the various operations
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Prevents equipment from breaking down or malfunctioning.
Operators know they must keep their machines in good condition and eliminate the three evils.

47. What is the purpose of Therblig analysis?
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
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Staying competitive with yesterday's products is difficult - if not impossible.
Helps you understand the facts as they are.

48. What are the different types of motions required for performing an operation? (Type 1 motions)
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.
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
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Can only be done when the machine is stopped or shut down.

49. What is pull production?
Time control and commitment
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
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

50. What are the motions that slow down Type 1 motions?
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)
To eliminate the big 3.
Zero monitor manufacturing
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.