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| OVER PRODUCTION (THE WORST WASTE) |
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| AVAILABLE WORK TIME/CUSTOMER DEMAND |
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| THE JAPANESE TERM CHAKU-CHAKU TRANSLATES TO |
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| LOAD-LOAD, THE PROCESS OF MOVING A PART EJECTED FROM ONE MACHINE AND LOADING IT INTO THE NEXT |
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| STANDARD WORK REDUCES _____IN PRODUCTION AND SHOW HOW_____IS PERFORMED. |
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| TYPE OF PRODUCTION THAT ENABLES SINGLE PIECE FLOW |
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| PEOPLE WHO TAKE CARE OF EVERYTHING OUTSIDE OF THE CELL, OFTEN CALLED MATERIAL HANDLERS |
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| STANDARD WORK DOCUMENTS THE___AND ____ |
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| ELIMINATING THE WASTE IS USUALLY NOT THE PROBLEM____ IS |
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| CRITICAL COMPONENTS OF BEING LEAN ARE ____ AND BEING_______ |
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| AUTOMATING THE WASTE OF MOTION IS AN EXAMPLE OF A _______ IMPROVEMENT |
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| WASTE CAN BE IDENTIFIED THROUGH____OBSERVATION |
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| SMALL CHANGE FOR THE BETTER |
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| POKA-YOKE SETS PEOPLE UP TO |
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| POKA-YOKE IS PART OF A SYSTEM OF |
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| _______INSPECTIONS ARE NOT ENOUGH |
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| _______ARE GOLD NUGGETS AND REPRESENT OPPORTUNITIES FOR POKA-YOKE |
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| _______SHOULD BE THOUGHT OF AS SCRAPPING TIME |
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| POKA-YOKE MEANS WITHOUT_______OR________ |
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| POKA-YOKE HAS THESE 3 THINGS |
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| LOW COST, 100% INSPECTION, IMMEDIATE FEEDBACK |
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| KAIZEN EVENTS ARE FOCUSED EVENTS TYPICALLY SCHEDULED OVER____DAYS |
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| WITHOUT A ____THERE CAN BE NO KAIZEN |
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| COMMANDMENTS OF KAIZEN ARE |
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| SEEK THE WISDOM OF 10 RATHER THAN THE KNOWLEDGE OF 1, CREATIVITY BEFORE CAPITAL, CREATE A BLAMELESS ENVIRONMENT, KEEP A POSITIVE ATTITUDE, GAIN EMPLOYEE INVOLVEMENT, IF SPENDING MONEY - SIMULATE FIRST, KEEP AND OPEN MIND, THINK HOW TO DO IT RATHER THAN WHY IT CANNOT BE DONE, NEVER LEAVE IN SILENT DISAGREEMENT |
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| TWO GOALS OF KAIZEN EVENTS ARE TO_____AND_____ |
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| SOLVE PROBLEMS, ELIMINATE WASTE |
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| DURING PREPLANNING OF THE KAIZEN EVENT, THE____OF THE EVENT IS SET |
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| A BROADER DEFINITION OF KAZAN IS |
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| MAKE NEW, TAKE APART, THINK ABOUT |
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| EVERY KAIZEN EVENT SHOULD ADDRESS, ATA MINIMUM, ONE EACH_______ITEM |
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| SAFETY AND QUALITY RELATED |
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| Safety, Sort, Set in Order, Shine, Standardize and Sustain |
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| 6S is about creating a _____workspace that anyone can understand |
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| The 6th "S"______SOMETIMES LISTED AS THE FIRST "s", IS A BYPRODUCT OF A WELL IMPLEMENTED 5s SYSTEM |
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| AT THE HEART OF 6S IS____________ |
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| SUSTAINING IS ABOUT SELF-DISCIPLINE. THUS THE ULTIMATE GOAL OF SUSTAINING IS TO CREATE A PROCESS THAT DOES NOT REQUIRE____________ |
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| A PLACE FOR EVERYTHING AND EVERYTHING IN IT'S PLACE IS WHAT "S" |
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| LOCATING ITEMS AT THEIR POINT OF USE REDUCES________WASTE |
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| THE MOST IMPOPRTANT "S" IS______ AND MUST BE THE TOP PRIORITY OF AND IMPROVEMENT EFFORT. |
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| RED TAGGING OF ITEMS OCCURS DURING THE______PROCESS |
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| AN EFFECTIVE METHOD OF SUSTAINING 6S IS THROUGH_________ |
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| SHINING IS MORE THAN CLEANING, IT INCLUDES__________ |
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| 6S PROVIDES A SET OF TOOLS FOR CLEANING, ORGANIZING, DEVELOPING, AND______A PRODUCTIVE WORK ENVIRONMENT |
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| A TOOL OFTEN APPLIED TO HELP STANDARDIZE A PROCESS IS THE USE OF______ |
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| THE STRAIGHTENING PROCESS INCLUDES DECIDING WHERE ITEMS WILL BE LOCATED AND ADDING____________ |
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| RED TAGGED ITEMS INCLUDE ITEMS |
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| NO ONE WANTS AND SELDOM USED |
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| 6S IS A WORK ____, AND NOT_____APPROACH |
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| A KEY TO VISUAL CONTROLS IS THAT THEY ARE |
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| UNDERSTANDABLE AT A GLANCE |
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| SEPARATING THE NECESSARY FROM THE UNNECESSARY OCCURS DURING THE______PROCESS |
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| In the United States______of maintenance work is to fix something after it breaks versus performing preventative maintenance. |
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| TPM is a vital part of______ |
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| ___________maintenance is regarded as the ideal and most profitable type of maintenance. |
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| Performing a maintenance task every 60 days is ______ maintenance |
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| There are ____phases of attempting to get to zero equipment stoppages. |
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| Predictive maintenance should be the ___form of maintenance |
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| Contamination and improper lubrication account for_____of breakdowns |
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| A breakdown is typically ______ times the cost of performing preventative maintenance. |
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| Breakdowns and setup/changeover are considered____ |
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| Startup and defects are considered_____ |
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| Idling/stoppages and reduced speed are considered__________ |
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| overall equipment effectiveness |
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| What are the 4 phases of attempting to get to zero equipment stoppages |
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Definition
equipment failure history
predict equipment life
stabalize the failure interval
maintenance excellence |
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| Improving the equipment productivity translates into dollars. Collecting the data is the first step in this process. Which data is needed first |
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| equipment failure history |
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| Following maintenancepersonnel and mapping all their activities is called______ |
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| The ultimate "creativity killer" that can also be permanent is the word______ |
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| The status quo is a condition best described as______ |
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| A significant factor nesessitating the need for constant improvement is______ |
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| _____must come from the employees |
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| ___________begins by asking "what can I do?" |
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| Creating the right____is crucial to lean |
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| Single points in time where managers and supervisors determine the vector of momentum either positive or negative, and encourage the flow of potential improvements are known as________________ |
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| This % of objection is cautionary and is a normal response to change |
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| Management must create an environment that promotes____and allows more_____ to be presented. |
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| The "8th waste" is the waste of__________ |
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| THIS IS A RESULT OF HOW MANAGEMENT AND SUPERVISORS INTERACT WITH EMPLOYEES |
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| EMPLOYEES WHO ARE NOT INCLUDED IN THE DISCUSSION OF POTENTIAL CHANGES WILL USUALLY ______THE CHANGE |
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| SMALL CHANGES OF CONTINUAL IMPROVEMENT DONE BY THE PEOPLE, AND NOT TO THE PEOPLE, ARE KNOWN AS______EVENTS |
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| THIS STARTS WITH MANAGEMENT AND SUPERVISION |
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| FLOW IS IMPORTANT IN LEAN OPERATIONS, MAKE ONE, PASS ONE, IS AND EFFECTIVE WAY TO PRODUCE WHEN TRYING TO____ |
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| A COMMON TRAIT OF LEAN ORGANIZATIONS IS_____ |
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| visual management techniques, standard work, flexible work spaces |
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| THE FOLLOWING ARE REQUIRED FOR THE ACCEPTANCE OF LEAN |
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| GENUINE COMMITMENT OF ALL EMPLOYEES, ACCEPTABLE WORK PACE, TRAINING AND CONTINUAL IMPROVEMENT |
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| WHEN QUALITY OF THE PRODUCT INCREASES, PRODUCTION COSTS______ |
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| WHAT ARE THE TRIGGER MECHANISMS FOR A KANBAN SYSTEM |
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| MARKED FLOOR SPACE, EMPTY BINS, CARDS |
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| TWO ESSENTIAL CONCEPTS OF LEAN INCLUDE |
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| QUALITY AT THE SOURCE AND PULL |
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| LOWER PRODUCTION COSTS, HIGHER QUALITY, SHORTER CYCLE TIME |
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| LEAN IS A ________THAT MAPS THE PROCESS FROM START TO FINISHED GOODS TO THE CUSTOMER |
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| LEAN EXPANDS VALUE-ADDED ACTIVITY AND REDUCES_____ |
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| NON-VALUE-ADDED ACTIVITIES |
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| A SYSTEMATIC, COMMON SENS APPROACH TO IDENTIFYING AND ELIMINATING WASTE THROUGH CONTINUAL IMPROVEMENT |
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| TO FIND NEW CHEESE REQUIRES ONE TO MOVE IN A ____DIRECTION |
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| DECIDING TO GO BACK INTO THE MAZE,HAW FOUND HIMSELF HAVING TO FACE AND OVERCOME HIS___ |
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| LAUGHING AT HIMSELF, HAW EXCLAIMS, "WE KEEP DOING THE SAME THINGS OVER AND OVER AGAIN AND WONDER WHY________" |
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| POSESSING A VISION OF HOW THINGS CAN BE BETTER IS SEEING____ |
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| IN A NOTE TO HEM, HAW WRITES, "IF YOU DO NOT CHANGE, YOU BECOME______" |
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| WITHIN DPS, _____IS THE HIGHEST LEVEL OF LEAN CERTIFICATION AND INDIVIDUAL CAN OBTAIN, |
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| EXAMPLES OF VALUE STREAM MAPS CAN BE FOUND IN THE ____SECTION |
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| THE DPS CONTAINS____GUIDING PRINCIPLES |
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| WHICH IS THE HIGHEST PRIORITY IN THE DPS? |
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| WHAT ARE THE DPS SUB-SYSTEMS |
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| CULTURAL SYSTEM, LEADERSHIP SYSTEM, OPERATING SYSTEM |
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| IN THE OPERATING SUB-SYSTEM____TOOLS ARE DESCRIBED |
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| THE LEAN LIBRARY RECOMMENDS THIS MANY DIFFERENT TITLES |
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| THE DPS IS DEPICTED IN THIS TYPE OF SHAPE |
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| THE PLACE HWERE VALUE IS CREATED IS KNOWN AS THE______ |
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| THE DPS EXPECTS EVERYONE TO |
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| CHALLENGE THE STATUS QUO, TO INVOLVE ALL STAKEHOLDERS IN CHANGE |
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| THE EFFECTIVENESS OF LEAN TRAINING IS INCREASED WHEN THE TRAINING IS RELATED TO EMPLOYEES_____ |
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| FOOD DRIVES, SCHOOL SUPPLY DRIVES, AND COMMUNITY PROJECTS CAN ALL HELP TO |
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| EMPLOYEES REACHING THE THIRD LEVEL OR STAGE OF PROBLEM SOLVING OFTEN STATE________ |
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| WE HAD A PROBLEM, COME SEE HOW WE SOLVED IT |
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| ______ARE THE KEY TO MAKING A LEAN TRANSFORMATION SUCCESSFUL |
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| THE SHINGO PRIZE FOR EXCELLENCE IN MANUFACTURING IS AWARDED TO ORGANIZATIONS THAT________________ |
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| USE AND EXPAND ON THE IDEAS OF LEAN MANUFACTURING |
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| CAVE IS AN ACRONYM FOR____________ |
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| CITIZENS AGAINST VIRTUALLY EVERYTHING |
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| MULTIPLYING THE NUMBER OF LATE LINES BY THE NUMBER OF DAYS LATE IS A CALCULATION OF THE_________ |
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| VALUE STREAM MAPPING (VSM) ALWAYS STARTS AND ENDS WITH |
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| THE FINAL PHASE OF VALUE STREAM MAPPING IS DEVELOPING AND IMPLEMENTING ______TO ACHIEVE THE FUTURE STATE |
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| THE UPPER TIME-LINE ON THE VALUE STREAM MAP REPRESENTS_____WORK |
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| BEFORE MAKING AN IMPROVEMENT YOU NEED TO KNOW WHY IT IS IMPORTANT TO MAKE___________ |
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| a_____WAS/IS USED BY TOYOTA TO DEPICT INVENTORY ON THE VALUE STREAM MAP |
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| DIVIDING THE AVAILABLE WORK TIME BY THE CUSTOMER DEMAND RESULTS IN A _____ |
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| FLOW KAIZEN LOOKS AT THE_____BUSINESS |
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| A CURRENT STATE MAP PROVIDES A HIGH-LEVEL VIEW OF THE______IN THE SYSTEM |
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| A VALUE STREAM MAP FOLLOWS THE FLOW OF ALL OF THE FOLLOWING |
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| INVENTORY, INFORMATION, INSPECTION |
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| THIS TYPE OF FLOW HELPS YOU UNDERSTAND WHY INVENTORY IS BEING CREATED |
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| WHEN PEOPLE FOCUS ON OPTIMIZING PIECES OF THE SYSTEM INSTEAD OF THE WHOLE SYSTEM, THEY ARE APPLYING____THINKING |
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| THE LOWER TIME-LINE OF THE VALUE STREAM MAP REPRESENTS_____WORK |
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| GOING AND SEEING IS REPRESENTED BY____ON THE VALUE STREAM MAP |
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| THE VALUE STREAM MAP IS DIVIDED INTO |
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| INFORMATION FLOW, MATERIAL FLOW, PHYSICAL TRANSFORMATION PROCESS |
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| VALUE STREAM MAPS ARE BEST DRAWN |
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| WHEN A MACHINE IS FACED WITH AN UPCOMING CHANGEOVER IS RUNNING, ____SETUP SHULD BE PERFORMED |
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| THE FIRST STEP IN UNDERSTANDING EXACTLY HOW SETUP REDUCTION CAN BENEFIT AN ORGANIZATION IS TO FIGURE OUT HOW LONG_____PRESENTLY TAKE |
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| INCLUDING THE ______IS ESSENTIAL WHEN LOOKING TO MAKE CHANGEOVER IMPORVEMENTS |
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| REGARDLESS OF THE PROCESS, LONG CHANGEOVERS______ |
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| QUICK CHANGEOVER WILL LEAD TO_____ |
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| SETUP REDUCTION IS A KEY TOOL FOR BEING ______, ________ AND__________ |
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| FAST, FLEXIBLE AND RESPONSIVE |
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| WHEN A MACHINE FACED WITH AN UPCOMING CHANGEOVER IS NOT RUNNING, ____SETUP SHULD BE PREFORMED. |
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| THE TIME BETWEEN THE LAST PRODUCTION RUN AND THE FIRST GOOD PIECE FROM THE NEXT RUN |
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| EMPLOYEE BUY-IN AND____ARE IMPORTANT COMPONENTS OF QUICK CHANGEOVER |
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| SETUP REDUCTION IS NOT ABOUT______ |
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| _______WILL HELP TO ACHIEVE SIGNIFICANT GAINS RESULTING FROM SETUP REDUCTION |
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| SETUP REDUCTION IS ABOUT_____ |
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| ELIMINATING NON-VALUE-ADDED ACTIVITIES |
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| __________IS AN EXAMPLE OF AN ACTIVITY THAT SHOULD BE PERFORMED AS PART OF THE INTERNAL SETUP |
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| SETUP REDUCTION CAN GENERATE SIGNIFICANT BOTTOM-LINE BENEFITS TO AN ORGANIZATION; OFTEN WITH LITTLE OR NO_____ |
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| _____IS AN EXAMPLE OF AN ACTIVITY THAT SHOULD BE PREFORMED AS PART OF THE EXTERNAL SETUP |
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| STAGING OF DIES AND EQUIPMENT, GATHERING TOOLS REQUIRED FOR PERFORMING THE CHANGEOVER, PAPERWORK |
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| THE USE OF KANBAN IS ONLY A SUBSTITUTE FOR NOT BEING ABLE TO IMPLEMENT_________IN YOUR PROCESS |
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| AN IDEAL STATE WOULD BE______THROUGH ALL THE MAIN PROCESSES AND SUB-PROCESSES |
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| THE BASIC KANBAN ACTIVATES______WHEN THE PEOPLE IN A DOWNSTREAM PROCESS COME TO THE UPSTREAM PROCESS TO WITHRDAW THE CORRECT QUANTITY OF THE PARTS AT THE RIGHT TIME. |
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| KANBAN IS THE JAPANESE TERM FOR A VISUAL SYSTEM WHICH IS USED TO TRIGGER ACTIVITY______IN A GIVEN PROCESS |
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| __________IS THE LEAST WASTEFUL METHOD TO PRODUCE GOODS AND SERVICES |
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| _______PRODUCTS SHOULD NEVER BE TRANSPORTED TO THE DOWNSTREAM PROCESS |
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| THE UPSTREAM PROCESS SHOULD PRODUCE THE PARTS OR PRODUCT IN THE QUANTITIES WITHDRAWN BY THE_____________ |
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| THE KANBAN SYSTEM CONTAINS THE CRITICAL INFORMATION THAT CONTROLS THE PRODUCTION OF THE RIGHT____, IN THE RIGHT_____, AND THE RIGHT_________ |
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| KANBAN SYSTEMS PERFORM ALL OF THE FOLLOWING |
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| VISUAL CONTROL, REDUCTION OF INVENTORY, INSTRUCTION |
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| THE BEST KANBAN SYSTEM IS________ |
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| KANBAN CAN BE UTILIZED TO ADAPT TO_____ __________IN PRODUCTION |
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| THE QUANTITY OF PARTS CONTAINED IN A KANBAN CONTAINER MUST BE_____THE KANBAN |
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| ATTEMPTS TO ELIMINATE KANBAN SHOULD FOCUS ON |
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| STANDARDIZATION OF JOBS AND IMPROVING MACHINE LAYOUT |
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| ATTEMPTS TO ELIMINATE KANBAN SHOULD FOCUS ON |
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| AS EACH SUB-PROCESS WITHIN AN ORGANIZATION IS CONNECTED BY A KANBAN SYSTEM, THE ENTIRE PROCESS BEGINS TO ACT AS A ____WHERE THE PRODUCT IS PULLED TO THE CUSTOMER DEMAND |
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