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 flowcharting rules of construction?
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 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.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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

2. What are the three evils?
Doubling productivity - Productivity = Output / TEE
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.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Contamination - inadequate lubrication - misoperation

3. What is the purpose of video analysis?

4. What is level 4 of key 9?
Made the basic elements of human motion (therbligs)
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
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.

5. What is level 5 of key 9?
Made the basic elements of human motion (therbligs)
No one realizes that monitoring is waste - not work
Machines work together to prevent overproduction - it stops once it meets demands.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

6. What is preventative maintenance?
Eliminate certain processes that produce or create waste.
Identifying problems before they cause breakdowns.
Large scale improvement
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

7. What is product flow charting?
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
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Study the flow of a product through the various operations

8. What are the benefits of quick changeover for companies?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Emphasize the connections between processes and full employee participation in improvement making
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

9. What are the three key technical activities in a TPM program?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Video tape a person doing this so they can review what they're doing and improve.
Preventative maintenance - Prevention maintenance - Corrective prevention
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

10. What is key #7?
Zero monitor manufacturing
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Anyone could find any file within one minute.
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

11. What is the new product introduction loop?

12. What are the motions that do not perform an operation?
Cycle time - work sequence - standard inventory
Industrial engineering methodologies
You have to communicate! Coordinate where the output is going to be stored.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

13. What are the 6 Big Losses of TPM?
Factory employees begin setting up inter-process stores
Executives do not understand the high rate of return linked to integrated improvement.
Identifying problems before they cause breakdowns.
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 is the make/ship loop?
It's hard because it deals with attitudes of employees.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Backorders create complacency.

15. What is level 3 of key 10?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Identifying problems before they cause breakdowns.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Supervisors meet to work out time control issues

16. What is the trouble with large-lot production?
Inventory waste - Delay - Declining quality
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Maintaining equipment
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

17. What are the steps in motion study?
Eliminate certain processes that produce or create waste.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Helps you understand the facts as they are.
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

18. What are the three pillars of lean systems?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Everyone understands the need for PM; PM has been implemented for the most important machines.

19. What is the purpose of Cyclegraphic analysis?
Study the flow of a product through the various operations
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)
Filming someone with a light on their finger so you can see the movements to better improve the design.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

20. What is level three of key 7?
Anyone could find any file within one minute.
You want to equalize your work loads in terms of your lot size - one-piece flow.
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 only be done when the machine is stopped or shut down.

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

22. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
No one realizes that monitoring is waste - not work
Time it takes to make one unit

23. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

24. What is production leveling?
Factory employees begin setting up inter-process stores
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
You want to equalize your work loads in terms of your lot size - one-piece flow.

25. What has to be done to get to level two of key 8?
You have to communicate! Coordinate where the output is going to be stored.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Determining the life expectancy of components in order to replace them at the optimum time.
Industrial engineering methodologies

26. What is the value of TPM?
Factory employees begin setting up inter-process stores
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.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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.

27. What is kaizen?
Continuous improvement of person and process
Factory employees begin setting up inter-process stores
Emphasize the connections between processes and full employee participation in improvement making
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

28. What is multi-process handling?
One operator handling several machines or processes
People have learned how to make systematic improvements at each process.
Operators know they must keep their machines in good condition and eliminate the three evils.
The available production time divided by the rate of customer demand

29. What is key #8?
Coupled manufacturing
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
Identifying problems before they cause breakdowns.

30. What is operator flow charting?
Study the movement and motions of a worker or associate
Doubling productivity - Productivity = Output / TEE
Made the basic elements of human motion (therbligs)
Preventative maintenance - Prevention maintenance - Corrective prevention

31. What is level five of key 5?
Time control and commitment
Preventative maintenance - Prevention maintenance - Corrective prevention
Machines work together to prevent overproduction - it stops once it meets demands.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

32. What is an external setup element?
Maintaining equipment
Quick changeover technology
Can be done while the machine is still processing.
The available production time divided by the rate of customer demand

33. What is the purpose of Therblig analysis?
Time control and commitment
Everyone recognizes that monitoring is waste
Work and break times are left to the workers' discretion
Helps you understand the facts as they are.

34. What is level two of key 5?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Video tape a person doing this so they can review what they're doing and improve.
Cycle time - work sequence - standard inventory
Anyone could find any file within one minute.

35. What appears to be the primary metric in key 6?
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.
Can only be done when the machine is stopped or shut down.
Time measuring
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

36. What does TPM do?
The available production time divided by the rate of customer demand
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Prevents equipment from breaking down or malfunctioning.

37. What is level three of key 8?
Filming someone with a light on their finger so you can see the movements to better improve the design.
The available production time divided by the rate of customer demand
Factory employees begin setting up inter-process stores
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

38. What is level 3 of key 9?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Operators know they must keep their machines in good condition and eliminate the three evils.
People have learned how to make systematic improvements at each process.

39. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
It's hard because it deals with attitudes of employees.
Quick changeover technology
Time measuring

40. What does kanban do?
Everyone understands the need for PM; PM has been implemented for the most important machines.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Determining the life expectancy of components in order to replace them at the optimum time.

41. What is level two of key 8?
The customer's order starts the process
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
Emphasize the connections between processes and full employee participation in improvement making
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.

42. What is the strategic business development loop?
Maintaining equipment
To eliminate the big 3.
You have to communicate! Coordinate where the output is going to be stored.
Executives do not understand the high rate of return linked to integrated improvement.

43. What is kaikaku?
Double capacity and the per unit production cost is 60% of the lower capacity option.
Large scale improvement
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
You want to equalize your work loads in terms of your lot size - one-piece flow.

44. What is push production?

45. What is level five 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.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
The customer's order starts the process
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

46. What is corrective maintenance?
Knowledge - Job security - Safety - Simplicity
Manufacturing value analysis
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

47. What is level two of key 6?
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 it takes to make one unit
You want to equalize your work loads in terms of your lot size - one-piece flow.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.

48. What is the main goal of MVA?
Doubling productivity - Productivity = Output / TEE
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
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 mistakenly think that increasing lot sizes is a good way to reduce changeover time.

49. What is full work system?
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.
Machines work together to prevent overproduction - it stops once it meets demands.
Operators know they must keep their machines in good condition and eliminate the three evils.

50. What are the process improvement steps?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
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
Anyone could find any file within one minute.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.