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. E.g. during changeovers - for work - queues - equipment down - needing feedback from customer - Pull system - Reduce changeover times - Preventive maintenance






2. Globalisation - Innovation/technology - Costs - Competitiveness - Quality - Customer service (including internal customers) - Risk management - Environment (physical)






3. Change for the better - continuous improvement






4. Overall equipment effectiveness: availability x performance x quality yield measured in hours






5. Structured methodology of sequence of activities aimed at removing waste by improving organisation - visual communication and overall cleanliness. Sort - keep only what you need Set in Order - A place for everything and everything in its place Sh






6. Product portfolio - Product design - Variety in parts/raw materials - Manufacturing process - Inventory (BTO or BTS) - Distribution - Vendor partnerships - Logistics






7. Visual 'call for help' system - means a Japanese paper lantern






8. 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?






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






10. Failure mode and effects analysis. Identify every possible failure mode of a process or product - with the aim of determining the effect on other sub-items and on the required function of the product or process






11. 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






12. Usually around 8-10%






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






14. 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






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






16. Non value added time. The potential non-production time that can be eliminated from a process






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






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






19. Aligning manufacturing output with customer demand to calculate safety stocks and Kanban levels - and at the same time provide a saving to the organization by reducing the amount of money tied up in inventory






20. Value added time + nva time... time it takes to go through all the elements of a process before the activity repeats






21. Define measure analyse improve control






22. Cumulative trauma disorder






23. In theory of constraints drum is the rate of the constraint - buffer is stocks to supply - rope is limit on upstream production to prevent flooding.






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






25. Try to defer variation - keep generic for as long as possible






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






27. 99.99966% good






28. Specific - Measurable - Achievable - Realistic - Timetable/ time based / timely






29. Each step in process should be as close to Takt time as possible






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






31. Value (what customer will pay for - ask them)- Value Stream (all processes that add value) - Continuous Flow (linking - avoid stagnation) - Pull (demand - nothing produced until signalled for) - Perfection (an ideal)






32. 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






33. Factors that influence addition of value: technology quality reliability delivery customer service and environment






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






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






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






37. Plan Do Check Act






38. 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)






39. Rework - repair - incorrect info. Due to poor training - tools - layouts - process failures - established standards - checklists - forms. - Visual controls - 5 Whys RCA - PDCA - Poke Yoke






40. Transport - Inventory - Motion - Waiting - Overproduction - Overprocessing - Defects






41. What's in it for me?






42. 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






43. Enterprise Resource Planning eg SAP - JD Edwards






44. Material requisition planning






45. 1. Value Proposition - it is easy to identify stakeholders - it is very difficult to understand what provides value to stakeholders 2. Value Identification - structure value streams based on the stakeholders' value propositions so that people - g






46. Minimum order quantity






47. Procurement - Manufacturing - Warehousing - Distribution - Customers






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






49. More information or material than process needs eg unnecessary files - long equipment setup - poor communication with suppliers. Minimum order quantities adjustments. - Reduce batch size - 5S - Load levelling - Pull system eg Kanban






50. 3 line graph showing product - service - internal scrap - Vertical y axis defect rate - Horizontal x axis the various stages of the process