Exam Questions '19

Question 1

Assembly Line Production by Henry Ford: 5 Advantages

Answer 1

• Less interim storage through avoidance of semi-finished goods
• Sequently arranged workplaces – shorter distances & lower transport costs
• Specialisation & division of labour – cost advantages
• Low skill jobs – faster adjustment of new employees
• Integration of quality control

Question 2

Assembly Line Production by Henry Ford: 5 Disadvantages

Answer 2

• Lower flexibility of workers
• Higher capital requirements and capital lock-up
• Limited workers freedom in case of unexpected problems
• Monotone work – lack of motivation
• Less socialising among workers

Question 3

Definition of GEMBA

Answer 3

Gemba is the place where value adding activities are carried out and means in a broad sense the areas of development, production and sales. It is used to emphasise the importance of the shop-floor and the work done there as a target for improvement, and so will be inspected on the so called gemba walks.

Question 4

5 Golden rules of GEMBA

Answer 4

o When a problem arises go to gemba first
o Check the relevant objects (gembutsu)
o Take temporary counter measures right away
o Find the root cause
o Standardize to prevent recurrence

Question 5

PDCA Cycle - 7 Steps

Answer 5

1. Describe the problem
2. Recognize the causes
3. Determine improvements
4. Develop, asses and plan measures (PLAN)
5. Implement measures (DO)
6. Compare outcome to target (CHECK)
7. Introduce standard (ACT)

Question 6

PDCA Cycle - Match 4 Tools / Methods to the steps

Answer 6

Plan changes for improvement 
o	Customer / Supplier Mapping 
o	Pareto analysis
o	Flow charting
o	Brain Storming 
Do small scale changes for trial
o	Customer / Supplier Mapping 
o	Small-group leadership skills
o	On-job training 
o	Experimental design 
Check if changes work and investigate selected processes
o	Customer / Supplier Mapping 
o	Control Charts 
o	Graphical analysis
o	KPI
Act to get the greatest benefits from the changes
o	Customer / supplier mapping
o	Process mapping 
o	Process standardization 
o	Training

Question 7

List and explain the 5 types of global production networks

Answer 7

• Global factory: Factories deliver globally, produce locally (high EoS, low significance of local adaption)
• Chain: Concentration in production (globally) steps (Medium EoS, low significance of local adaption)
• Net: Global and close linked network (Low EoS, low significance of local adaption)
• Hub and Spoke: EoS and local preference (high EoS, high significance of local adaption)
• Local: Local production for local market (low EoS, high significance of local adaption)

Question 8

List and explain all steps of an 8D report (problem solving)

Answer 8

1. Establish team: members need knowledge to understand and analyse process to find the cause of error, design countermeasures and watch over implementation.
2. Define and describe Problem: select quantitative standards and describe problem precisely to measure level of success afterwards.
3. Define intermediate procedures: Interim Actions to limit damage until countermeasures are implemented
4. Identify root cause: use different tools to gain deep understanding of the problem
5. Plan Long time countermeasures: should rule out any reoccurrence of the problem
6. Establish countermeasures: All actions need to be taken according to plan
7. Evaluate the problem solving: check whether countermeasures have the planned effect
8. Appreciate team achievements: recognise collective efforts, formal thanking by organisation

Question 9

5 Steps in LCA

Answer 9

1. Maximise equipment efficiency (right equipment, right time)
2. Synchronise value stream (synchronised cycle times)
3. Improve mistake autonomy (sensors to detect mistakes)
4. Decrease equipment costs (same machines, same spareparts)
5. Simplify the transport (more good parts, less transport for broken pieces)

Question 10

Targets in TPM – Total Productive Maintenance

Answer 10

• Cost (Maintenance, energy, piece)
• Security and Environment (accidents, waste, emissions)
• Quality (Scrap rate, rework rate)
• Delivery (del. time & reliability)
• Productivity (OEE, throughput)
• Motivation (Fluctuation of Employees, no of CIP ideas)

Question 11

Sustainable Manufacturing - Meaning and 3 strategies

Answer 11

Sustainable Manufacturing
Meaning: Development of technologies to transform materials without emissions and generation of losses.
1.	Reduce: Design for use 
2.	Reuse: Design for durability 
3.	Recycle: Design for disassembly

Question 12

5 Types of wastage in production related information flows & examples

Answer 12

1. Overproduction: more information than needed
2. Stocks: different versions of documents
3. Waiting Time: Inefficient release times
4. Communication: Information does not reach everyone
5. Incorrect docs: Need of further inquieries

Question 13

5 spheres of activities in Lean Development + example

Answer 13

1. R&D Strategy develop USPs
2. R&D Structure Centralised / decentralised organisation
3. R&D Leadership Innovation Culture
4. R&D Process Optimised level of detail
5. R&D Project Management KPI Cockpit

Question 14

5 characteristics of traditional offices + 5 characteristics of Lean Offices.

Answer 14

1. Unclear job  Written and well-defined job
2. Individual Accountability  team accountability
3. Few cross-functional relationships  open commun. & information flow
4. No conscious improvement methods  passion for CIP
5. Measures not linked to strategy  clear understanding of company goals

Question 15

Technical steps to implement Lean Administration

Answer 15

1. Improve self-organisation
2. Improve cooperation
3. Improve processes
4. Stabilize processes