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Lean Bronze Certification
questions and answers
Continuous Flow - answer high production volume, highly standardized commodity products Jidoka - answer automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur Autonomous Maintenance - answer An improvement process focused on improving the condition of a machine and then identifying, standardizing and training on operator maintenance tasks Andon light - answer Signal for a need or problem with equipment or process. Example of visual management A3 document - answer This helps to capture and share knowledge in a structured way. Its commonly used as a problem-solving tool. This should also be used as a coaching tool between a coach and a learner. Reference Managing to Learn by John Shook. Empowered Employees - answer The heart and soul of a lean organization according to Masaaki Imai (Gemba Kaizen) Sort - answer The first step of 5S Highland Park - answer The Ford Factory that housed the Model T production
consensus - answer A general agreement by team members. Not everyone may fully agree with the idea but no one is openly opposed and they can "live with it". Goal of Hoshin Kanri - answer To align the tactical actions and improvements to the strategic objectives of the business. This is a layered process which should be flowed from the higher level group and then down to the next level. cross-functional team - answer Employees from different areas coming together to complete a task or solve a problem Sequential pull system - answer A type of system is used when product variation is high and it doesn't make sense to keep an inventory of each product. With this type of system, we control the overall inventory in the system by only releasing when a trigger is created. interchangeable parts - answer According to Dennis (Lean Production Simplified), the greatest enabler of mass production Standardized Work & Jidoka - answer "Separating Man from Machine" describes the ability to have one operator run multiple machines. This is enabled by Standardized Work - answer Route of the operator is clear and documented Little's law - answer The relationship between work in process (WIP), throughput and lead time
NUMMI - answer The name of the joint venture between GM and Toyota Concentration diagrams - answer "Measles Charts" are another way to describe what tool Taiichi Ohno - answer Who is most often referred to as the godfather of lean manufacturing Reduction of changeover times - answer SMED (Single Minute Exchange of Dies) focuses on Value Stream Mapping - answer Learning to See by Shook and Rother is widely regarded as the foundation of what JIT and Jidoka - answer The pillars of the Toyota Production System (TPS) Red tag area - answer During the 5S Sort phase, where should we put items that we don't think we need Gemba walks - answer An opportunity for leaders to walk the floor, ask questions, understand reality and learn inventory - answer According to Womack and Jones (Lean Thinking) the simplest and most effective lean measure. This primary waste is reduced when pulling demand from the customer. Considered the worst type of waste
overprocessing - answer Doing more work than is required to satisfy the customer's requirements. Characteristics of craft production - answer high cost, unpredictable quality, long leadtimes and low volumes. Overproduction - answer Making parts just in case is an example of Takt Time - answer Helps to establish the pace of production in the business Capacity - answer Total Production Time Available / (Process Time + Setup/Interval) Poka Yoke - answer an error or mistake proofing tool and helps us build quality into the process Product mix - answer main difference between the application of the Ford System and the Toyota Production System Bottleneck - answer Any operation where the cycle time exceeds the takt time is defined as Identify the customer and define value - answer The first step in value stream mapping Water spider - answer An employee on the production floor who delivers and picks up material at the pace of production is known as a
Product Family Matrix - answer A tool that helps a company understand the different value streams they have is called a: rythum - answer Takt time is one of the basic lean guidelines that help us develop a future state. In German, the word takt is most closely related to what concept Risk Priority Number (RPN) - answer RPN = Severity x Occurance x Detection cycle time - answer The amount of time it takes to complete one piece at a process step is known as: DMAIC - answer The problem solving process most commonly associated with Six Sigma is: training - answer Goals in an organization cannot be achieved without adequate time allowed for learning organization - answer operates from common goals developed by the organization's stakeholders Automation and JIT - answer The two pillars of the Toyota Production System are: Standardized work - answer A lean concept that refers to the best combination of man, machine, materials and methods
Visual management - answer Making everything simple, clear and easy to understand at a glance in a work area is an example of: work cell - answer The layout of machines into a tight sequence, typically in a U-shape is called a retention time - answer Value stream lead time is comprised of cycle time and: decrease flexibility - answer Long set ups Most likely will: Effective Suggestions programs - answer These programs encourage idea generation and reward team member initiative Total Quality Control (TQC) - answer An integrated effort aimed to drive continuous improvements at all levels perfection - answer the complete elimination of waste so that all activities along a value stream create value Quality, cost, delivery (QCD) - answer The key focus of the Toyota Production System is to improve: Customer - answer Value is defined by machine and employee Utilization - answer These metrics serve as KEY performance measures in a "standard cost" accounting system?
training and practice - answer A commonality between sports and work is the continuing need for? Value Stream Map - answer This assists in identifying and eliminating all forms of waste Takt Time number - answer a product must be produced every time "X " seconds to meet customer demand life long learning - answer A lean system requires humility, respect for people and JIT - answer Kanban is a tool to support Bottleneck operation - answer The capacity of a process is limited by the : 5 - answer For most unimproved processes, the percent amount of value- added work relative to incidental work and waste PDCA - answer Strategic Policy Deployment (Hoshin Kanri) is the enterprise level application of: spaghetti diagram - answer This is used to identify physical flow within a process lean metrics - answer Measurements used to gauge problems, determine targets study the impact of improvement activities, check results, and make appropriate adjustments are known as:
Pareto Chart - answer This associates the sources of problems with the frequency of causes lead time - answer Production batch size is directly proportional to Kaizen - answer change for better = continuous improvement OEE - answer Availability x Performance x Quality Catchball - answer This is an approach, inspired by Hoshin Kanri, designed to incorporate feedback from employees when determining organizational direction. It's often used when developing things like mission statements and goals with the expectation that leadership and employees "toss" and "catch" each other's ideas and collaborate on the end result. Stability - answer What is the foundation of Toyota's House of Lean Production? Ishikawa diagram - answer Another common name for the Cause and Effect (Fishbone) Diagram is the: Leader Standard Work - answer a tool that helps to ensure leaders focus not only on results but the process as well. It focuses on changing management behavior to drive sustainment of implementation. Mura - answer Inconsistency or Variation
Automatic Maintenance - answer An improvement process focused on improving the condition of a machine and then identifying, standardizing and training on operator maintenance tasks Leadership - answer a cultural enabler of a lean culture? Balanced Scorecard - answer A measurement tool that generally has 4 categories (Customers, Internal, Financial and Innovation, and Learning) TIM WOOD - answer Acronym used to remember the seven wastes (Transportation, Inventory, Movement, Waiting, Overprocessing, Overproduction, Defects). 4Ms - answer When using Fishbone analysis, Toyota typically breaks down the potential causes using this Median - answer Skew is a measure of the symmetry of a data set. In a skewed distribution, which value is the best predictor?
