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Bronze_Lean
for Bronze Lean Cert Test
| Question | Answer |
|---|---|
| Acronym for “quick changeover” | SMED Single minute exchange of dies |
| Total # of items you should produce if the customer needs 7 | 7 |
| The “P” in TPM | Productive |
| Tool used to identify potential for improvement | Value Stream Map |
| Throughput improves as _____ is reduced | Leadtime |
| Japanese term for “WASTE” | Muda |
| 6 S | Safety, sort, straighten, shine, standardize, sustain |
| What is “COMMWIP” | Acronym describing 7 forms of waste |
| “COMMWIP” stands for? | Correction, overproduction, motion, material movement, wait, inventory, process |
| Preparation & setup that can occur without stopping production | External |
| Balance work among team members with an Operator _____ Chart | Loading |
| Program to enable improvement participation | Minor Kaizen |
| Type of waste resulting from multi storage locations for the same item | Material movement |
| Type of waste observed when repairing defects | Correction |
| Each step in a process should _____ from the upstream process step | Pull |
| The initials “VSM” stand for | Value Stream Map |
| A system to sequence production of products with varying labor content and demand | Heijunka |
| Another name for TPS Toyota Production System | Lean Manufacturing |
| Japanese term for radical change | Kaikaku |
| Ideal number of pieces processed in any process step when the total demand is ten | One |
| Calculation for takt time | Available Time/ Customer Demand |
| Without a _____ there can be no Kaizen | Standard |
| Changing fit, form or function of an item in a manner the customer is willing to pay | Value Added |
| Type of waste observed when sub-assembling items for a week’s worth of work | Overproduction |
| Type of waste observed when switching an air hose attachment from one tool to another | Motion |
| Prevents error from happening | POKA-YOKE |
| Define, measure, analyze, improve and _____ | Control “part of six sigma” |
| Six Sigma | Define, measure, analyze, improve, control |
| Number 1 priority of our company | SAFETY |
| Visual signal | ANDON |
| Maximum # of defects that should be passed forward | ZERO |
| What process performs an operation on all items in a group before proceeding to the next operation | Batch |
| Continuous improvement through incremental changes | KAIZEN |
| (Machine availability) X (Performance Rate) X (Quality Rate) = | OEE Overall Equipment Effectiveness |
| Card used to signal need for materials | Card used to signal need for materials |
| Systematic methodology for implementing rapid change through elimination of waste | Lean Manufacturing |
| 4 basic concepts of LEAN | Eliminate waste, visual, 5-S, standard work |
| Continued/uninterrupted progression of any activity | FLOW |
| Definition of Elimination of Waste | Produce right product at right time in right quantities for customer demand |
| Waste exists everywhere 5-M | Man, method, material, machine, money |
| Japanese word for “Go see the truth | GEMBA |
| Lean manufacturing Standardized System definition | Product flow, simplified practices, consistent methods, applying better ideas, leveled work loads |
| Area to sort items not needed | “Red Tag” |
| Acronym for board to post Safety, quality, delivery, inventory, 5-S | SQDIP |
| This presents the same information to everyone | Objectives of Visual Controls |
| What is MBWA | Management by walking around |
| Visual Management is see, respond, & adjust PDCA | Plan, do, check, act |
| Standard Work is | Standard work is a routine/sequence for work to be done, is the basis for improvement |
| Kai means | Good |
| Zen means | Change |
| Kaizen means | Change for the better or continuous improvement |
| Difference between man and machine | Machines depreciate & wear out/become obsolete Man appreciates, gains skills & knowledge |
| SDCA and PDCA | Standardize – Do – Check - Act Plan – Do – Check - Act |
| TPM is Total Productive Maintenance | TPM is a method for improving equipment or manufacturing processes, involves all people |
| Goals of a Pull System | One-piece production, perfect quality to customer, near zero lead time, only necessary inventory |
| Poka Yoke | Japanese term “mistake proof”, method of designing processes to prevent errors |
| Jidoka | Detects the error |
| 4 Levels of Quality | 1 – Customer inspects 2– End of line inspection 3 – End of Process inspect 4 – Perfect Quality built in |
| Value Stream Map shows | All the actions required to bring a product through its main flows to the customer |
| Current State Map shows & identifies what | Current State Map shows what is happening now, identifies waste, can see possible flow & pull |
| Standardized System will improve | Product flow, simplified practices, consistent methods, applying better ideas, leveled work loads |
| 6 Benefits of a Standardized System | 6 Benefits of a Standardized System |
| 7 Benefits of 5-S | Improve productivity, quality, safety, visibility management, work environment, identify normal vs abnormal, reduces floor space |
| Standard Work Needs | Takt time, work sequence, SWIP Standard work in process |
| A production system in which batches are used, where there is excessive WIP inventory | Push |
| Anything that does not add value is considered ______________ | Waste |
| We retain 80% of what we put into _______________ | Practice |
Created by:
xboxgmer
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