KAIZEN

Question 1

Maintenance

Answer 1

activities directed towards maintaining current technological, managerial operating standards and upholding standards

Question 2

Improvements

Answer 2

activities directed towards elevating current standard
emphasises human efforts, morale, communication, training, team-work, involvement and self-discipline

Question 3

PDCA cycle

Answer 3

Plan: establish a target
Do: implement the plan
Check: determine if implementation remains on track
Act: take actions to perform and standardise new procedures

Question 4

7 types of waste

Answer 4

Overproduction
Excess inventory
Scrap/Rework
Wait time
Excess conveyance
Excess motion
Overprocessing

Question 5

Overproduction

Answer 5

produce more than customer requires
producing too early

Question 6

Excess inventory

Answer 6

producing more than customer demand

Question 7

Scrap/Rework

Answer 7

things not done right the first time
consume labour, materials, energy etc. to remake
no value for customer

Question 8

Wait time

Answer 8

things always should be ready when required without delay

Question 9

Excess conveyance

Answer 9

moving parts more than required
often occurs with overproduction

Question 10

Excess motion

Answer 10

multiple handling of items, multiple trips to get materials, straining to reach tools etc.

Question 11

Over-processing

Answer 11

working the product beyond customer’s specification

Question 12

6-steps of kaizen

Answer 12

Discover improvement potential
Analyze current method
Generate new idea
Develop implementation plan
Implement the plan
Evaluate new method

Question 13

Discover improvement potential

Answer 13

establish new level of performance
requires more creativity, degrees of freedom and willingness to try new methods

Question 14

Kaizen attitude

Answer 14

Open-minded
Don’t be swayed by preconceived notion
Practice rigorous thorough observation of process
Conduct with calm and rational attitude

Question 15

Analytic skill for kaizen

Answer 15

Classify and organize
Quantify and observation
Specify the details

Question 16

Machine loss analysis

Answer 16

focus on human aspect of production

Question 17

Machine loss analysis areas for improvement

Answer 17

equipment breakdown
equipment changeover
equipment cycle time
minor stops
scrap/rework
start-up loss

Question 18

Equipment breakdown

Answer 18

unplanned downtime of machine due to electrical or mechanical failure
data on which component on machine breaks down
data on which machine breaks down
effective countermeasures can be taken

Question 19

Equipment changeover

Answer 19

lost production time due to changing tools in equipment
setup time reduction involves identifying major step during changeover
distinguish between work done before machine stop and after stopped
move work to external from internal

Question 20

Equipment cycle time

Answer 20

cycle time can degrade over time or be slowed
if unchecked accidental loss of production time can occur
if machine hasnt slowed down, there is still dead time in cycle

Question 21

Minor stops

Answer 21

machine often suffers minor stops that robs valuable production time

watching machine cycle continuously and interviewing machine operators can uncover minor steps for analysis regarding root cause
frequency of stops can be tabulated and corrective measures can be taken to eliminate them

Question 22

Scrap/Rework
(Machine loss)

Answer 22

dollar amount lost in production due to scrap/rework
time loss not so significant
many countermeasures available for any root cause

Question 23

Start-up loss

Answer 23

equipment starts up at beginning, prone to start-up problems or yield loss
cause equipment loss