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Lean Management

Instructions:

Answer 50 questions in 15 minutes.
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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 level three of key 6?
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
Double capacity and the per unit production cost is 60% of the lower capacity option.
Study the movement and motions of a worker or associate
People have learned how to make systematic improvements at each process.

2. What is the goal of motion study?
Backorders create complacency.
Involving production employees in the total machine maintenance process.
To eliminate the big 3.
Operators know they must keep their machines in good condition and eliminate the three evils.

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

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4. What are the three elements of the standard work sheet?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Filming someone with a light on their finger so you can see the movements to better improve the design.
Cycle time - work sequence - standard inventory
People have learned how to make systematic improvements at each process.

5. What is the 'Six-Tenths Rule'?
Eliminate certain processes that produce or create waste.
Contamination - inadequate lubrication - misoperation
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.

6. What is level four of key 5?
Filming someone with a light on their finger so you can see the movements to better improve the design.
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'.
Maintaining equipment
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

7. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Emphasize the connections between processes and full employee participation in improvement making
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

8. Full work systems
Made the basic elements of human motion (therbligs)
Identifying problems before they cause breakdowns.
Preventative maintenance - Prevention maintenance - Corrective prevention
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

9. What is level 4 of key 9?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Quick changeover studies begin; some employees are learning how to implement single changeover.

10. What are the 6 Big Losses of TPM?
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
Knowledge - Job security - Safety - Simplicity
Staying competitive with yesterday's products is difficult - if not impossible.
Time measuring

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

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12. What is the trouble with large-lot production?
Inventory waste - Delay - Declining quality
Large scale improvement
Cycle time - work sequence - standard inventory
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

13. At level three of key 6 - what is the methodology employees have been trained to use?
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
Contamination - inadequate lubrication - misoperation
Identifying problems before they cause breakdowns.
Industrial engineering methodologies

14. What is the purpose of video analysis?

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15. What is key 10?
Machines work together to prevent overproduction - it stops once it meets demands.
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.
Time control and commitment
All machines can operate during lunch without monitoring and many operators can handle two or more machines

16. What is level 5 of key 10?
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
Time measuring
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

17. What is the order processing and distribution loops?

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18. What is level one of key 5?
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.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
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

19. What is the value of TPM?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
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.
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 full work system?
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.
Zero monitor manufacturing
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.

21. What is level 2 of key 10?
Morning pep talk meetings are held everyday
The customer's order starts the process
Emphasize the connections between processes and full employee participation in improvement making
Coupled manufacturing

22. What are the three key technical activities in a TPM program?
Large scale improvement
Time control and commitment
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Preventative maintenance - Prevention maintenance - Corrective prevention

23. What is key #8?
Industrial engineering methodologies
Coupled manufacturing
Contamination - inadequate lubrication - misoperation
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

24. What is level 5 of key 9?
Run the machines into the ground
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

25. What is kaizen?
Continuous improvement of person and process
Helps you understand the facts as they are.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Doubling productivity - Productivity = Output / TEE

26. What are the five components of TPM?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Each section does its own thing; each workplace functions independently

27. What is corrective maintenance?
Coupled manufacturing
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
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.

28. What is level one of key 7?
No one realizes that monitoring is waste - not work
Time it takes to make one unit
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Time measuring

29. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Everyone understands the need for PM; PM has been implemented for the most important machines.
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.

30. What is predictive maintenance?
People have learned how to make systematic improvements at each process.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Determining the life expectancy of components in order to replace them at the optimum time.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

31. What is level 3 of key 10?
Supervisors meet to work out time control issues
Knowledge - Job security - Safety - Simplicity
The customer's order starts the process
Can be done while the machine is still processing.

32. What is level one of key 6?
Executives do not understand the high rate of return linked to integrated improvement.
Each section does its own thing; each workplace functions independently
There is a shotgun approach to improvements; people have little concern for improving methods.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

33. What are the flowcharting rules of construction?
Can be done while the machine is still processing.
Coupled manufacturing
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
There is a shotgun approach to improvements; people have little concern for improving methods.

34. What does manufacturing value analysis do?
Operators know they must keep their machines in good condition and eliminate the three evils.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Backorders create complacency.
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

35. What are the different types of motions required for performing an operation? (Type 1 motions)
The customer's order starts the process
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Can only be done when the machine is stopped or shut down.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

36. What is takt time?
Machines work together to prevent overproduction - it stops once it meets demands.
The available production time divided by the rate of customer demand
Time control and commitment
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

37. What did Frank Gilbreth do?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Made the basic elements of human motion (therbligs)
Quick changeover studies begin; some employees are learning how to implement single changeover.
Can only be done when the machine is stopped or shut down.

38. What is multi-process handling?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Workers are conscientious about sticking to the work throughout the designated working areas.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
One operator handling several machines or processes

39. What is level four of key 6?
Emphasize the connections between processes and full employee participation in improvement making
Anyone could find any file within one minute.
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
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

40. What is level 2 of key 9?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Everyone understands the need for PM; PM has been implemented for the most important machines.
Preventative maintenance - Prevention maintenance - Corrective prevention
Made the basic elements of human motion (therbligs)

41. What is autonomation (Jidoka)?
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)
Quick changeover technology
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

42. What is level two of key 8?
Emphasize the connections between processes and full employee participation in improvement making
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.
People have learned how to make systematic improvements at each process.
Cycle time - work sequence - standard inventory

43. What is level five of key 7?
It's hard because it deals with attitudes of employees.
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
Factory employees begin setting up inter-process stores
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

44. What are the process improvement steps?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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.
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

45. What is level five of key 8?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Doubling productivity - Productivity = Output / TEE
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Coupled manufacturing

46. What is prevention maintenance?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Operators know they must keep their machines in good condition and eliminate the three evils.
Supervisors meet to work out time control issues
Maintain normal conditions - early discovery of abnormalities - and prompt response.

47. What is preventive maintenance?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Determining the life expectancy of components in order to replace them at the optimum time.
People have learned how to make systematic improvements at each process.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

48. What is level three of key 7?
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
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Study the movement and motions of a worker or associate
Backorders create complacency.

49. What is level five of key 5?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
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'.
Industrial engineering methodologies

50. What is key #6?
Manufacturing value analysis
It's hard because it deals with attitudes of employees.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved 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