Test your basic knowledge |

Lean Supply Chain

Subject : business-skills
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. More work effort than necessary eg reviews - reports - cc-ing emails. Caused by lack of communication - teamwork - inappropriate decision making. Solved by focussing on customer value. - 5S - Value stream map - Whys RCA - PDCA






2. Material requisition planning






3. Endless transformation of waste into value from the customer's perspective Womack & Browne 1996






4. Value stream mapping simple process of directly observing the flows of information and materials as they occur - summarising them visually - and then envisioning a future state with much better performance 1. Locate operations 2. Identify area inve






5. Human foolproofing eg cannot insert 3-pin plug wrong way up






6. Usually around 8-10%






7. Walk through to identify processes - Gather all relevant information - document customer/supplier info and count inventory - Establish info flow - how does each process know what to make next? - Identify push v pull - Quantify process lead time v pro






8. Throw out old fixed ideas on how to do things - No blame - treat others as you want to be treated - Think positive - don't say you can't - Don't wait for perfection - 50% improvement now is fine - Correct mistakes as son as they are found - Don't sub






9. 3 line graph showing product - service - internal scrap - Vertical y axis defect rate - Horizontal x axis the various stages of the process






10. Buy - forecast - source - purchase - demand variability - Make - manufacture - assemble - planning - scheduling - Move - warehouse - distribution - logistics - timing - inventory - Sell - customer - demand - on-time






11. Procurement - Manufacturing - Warehousing - Distribution - Customers






12. Ship - store - move - make - pack - distribute - store - sell - return - service






13. Superset of process map - icons that allow capture of info / easy to understand - captures both material and information flow - identifies key info to prioritise what improvement actions should be initiated






14. The 4 ribs or bones are Man - Machine - Materials and Methods






15. Must all work together - Suppliers - Procurement - Operations - Warehousing - Transport - Customers






16. IT - Inbound logistics - Outbound logistics - Quality - Technology/design






17. eople - knowledge and skills - Tools and technologies - Physical facilities - where the value stream resides - Communication channels - Policies and procedures






18. What's in it for me?






19. Status quo unacceptable - Put aside preconceptions - Find root causes to problems - Focus on process not people - Employees are the experts - Allow yourself the right to fail (yeuch)






20. Produces just - what is needed - how much - when needed- where needed - Not just eliminating waste - enhancing value too






21. 99.99966% good






22. Visual description of an activity






23. Identify value - Map value stream - Create flow - Establish flow - Seek perfection






24. Excessive movement - includes document handoffs - Pull system eg Kanban - Reduce batch size - Load levelling






25. Shows movement through sequence of activities through top view - Plot to see how movement can be reduced






26. All activities associated with a product from raw material to final customer.






27. Gain corporate/top management vision - Train Lean champions/Kaizen facilitators - Access and develop the success structure - Identify the value stream - Get quick wins - Train associates and extend training to all - Engage and manage the supply chain






28. Single Minute Exchange of Dies - observe and record - separate internal and external - convert internal to external as possible - streamline activities - document






29. Design and manage the processes - flows and assets of material and information required to satisfy customer demands






30. All mfg inherently wasteful. ultimate in batch reduction is a single piece going through a process






31. Includes both va and nva activities unlike cycle time which is only the va activities. Confused by this. Processing time seems = VA activities. Process cycle is different?






32. Enterprise Resource Planning eg SAP - JD Edwards






33. Documentation aimed at performing task same way every time - current best way of doing an activity. Done with the people who do the work and OWNED by them. Uses: - drawings and photos - ensures consistency - developed with staff - readily accessible






34. Cumulative trauma disorder






35. Another 5S acronym - Cleaning/Arrangement/Neatness/Discipline/Organization






36. Focus on the biggest problem because it is the rate limiting step






37. Change for the better - continuous improvement






38. The minimum number of parts - including units in machines - required to keep a cell or process moving






39. Inbound: total cost of ownership - v quality - delivery schedule - flexibility - Outbound: customer satisfaction - v cost - flexibility - support level






40. Replenishment signal that authorises activity or delivery of required materials. Initiated by consumption - only happens for good parts - using the cell triggers the pull - nothing produced or moved without signal - only the kanban quantity delivered






41. Lean enterprise self assessment tool - proprietary MIT have to buy






42. First in first out first piece of inventory required in an operating step is the one delivered first






43. Unevenness - Rocks in the stream - hidden by inventory






44. Bringing people closer together for communication - One cell per product family - Bring together all the machines - Select appropriate tools - Aim is to have them independent - Train - balance workload - Reduce space and flow difference






45. Too much or too soon - excessive work in progress - Pull system eg Kanban - Batch size reduction- Load levelling






46. Quantity of inventory against time showing batch size at different points






47. Value left axis -Success probability right axis - height of bar shows effort involved?






48. Collaborative planning forecast replenishment -aka VMI






49. Identify and process value streams - Track waste and eliminate - Flow smoothly - Continuous improvement - Seamless integration with all parties






50. Anyone can assess conditions - Encourage participation reduce search time - Fewer questions - Better safety - Beter communication Examples: Tool board - visual kanban