LEAN

Question 1

Applies Lean to Time to Market process

Answer 1

Lean Development

Question 2

Lean metric based on the six big losses

Answer 2

OEE

Question 3

comparable to Formula 1 pit stop

Answer 3

SMED

Question 4

often organized in U-shaped layouts

Answer 4

Cellular Manufacturing

Question 5

allows close to zero defects

Answer 5

Six Sigma

Question 6

continuous improvement

Answer 6

Kaizen

Question 7

similar to scoreboards in sports

Answer 7

Visual Management

Question 8

also called supermarket principle

Answer 8

JIT-Production

Question 9

focuses on equipment related downtime

Answer 9

TPM

Question 10

lighters function based on this quality method

Answer 10

Poka-Yoke

Question 11

helps to achieve true Just-in-Time production

Answer 11

One-Piece Flow

Question 12

value & non-value adding times are key metics

Answer 12

Value Stream Mapping

Question 13

standardization is a key element

Answer 13

5S

Question 14

Problem-Solving Tool

Answer 14

A3

Question 15

Which LEAN tool acts as a KPI for quality?

Answer 15

Six Sigma

Question 16

Which LEAN tool acts as a KPI for time?

Answer 16

PCE

Question 17

Which LEAN tool is typically used in maintenance?

Answer 17

TPM

Question 18

Which LEAN tool is typically used in logistics?

Answer 18

Kanban

Question 19

Which LEAN tool is typically used in quality?

Answer 19

Poka-Yoke

Question 20

Which LEAN tool is typically used in production?

Answer 20

SMED

Question 21

What is considered perfect, world class, and typical performance in OEE?

Answer 21

100%, above 85%, above 60%

Question 22

Six Sigma allows how many defects/errors per million opportunities?

Answer 22

3.4

Question 23

JIT allows how many pieces per flow?

Answer 23

1

Question 24

lean metric based on the six big losses

Answer 24

OEE (Overall Equipment Effectiveness)

Question 25

What are the three goals of TPM?

Answer 25

1. Zero Accidents
2. Zero Defects
3. Zero Breakdowns

Question 26

What are the 5 parts to TPM?

Answer 26

1. Improvement Maintenance
2. Preventative Maintenance
3. Maintenance Prevention
4. 5S
5. Predictive Maintenance

Question 27

Car example for maintenance prevention

Answer 27

buy a new, reliable car from a manufacturer with excellent quality ratings (e.g. J.D. Power)

Question 28

Car example for preventative maintenance

Answer 28

clean, wash and wax your car; get routine service/inspections done as suggested by the manufacturer

Question 29

Car example for improvement maintenance

Answer 29

get occurred damages fixed immediately by the dealership or reputable repair shop

Question 30

Car example for 5S

Answer 30

familiarize yourself with your car and be able to identify any obvious issues (e.g. strange sounds); perform routine inspection tasks yourself
(e.g. check tire pressure, fluids)

Question 31

Car example for predictive maintenance

Answer 31

based on driven miles and wear, anticipate future needed improvements/repairs (e.g. brakes, tire replacement) and decide when replacement of car is more economical

Question 32

What’s the best method to display targets and statuses?

Answer 32

Using a visual scoreboard

Question 33

What’s the best way to help identify issues in production for downtime issues, material control, etc.?

Answer 33

Visual aids and panels

Question 34

What’s the main advantage of continuous improvement?

Answer 34

Some innovation leaps, but more continuous improvement - always getting better

Question 35

What are the 5S’s

Answer 35

Sort, set in order, shine, standardize, sustain

Question 36

Which Lean tool typically uses Kanban?

Answer 36

JIT production

Question 37

At a very basic level, SMED deals with what?

Answer 37

Reducing changeover time