Unit 1

Question 1

What is Kaizen

Answer 1

a continuous improvement tool, revolution in the way of working, where you look at processes and products and try to increase productivity over time.
The word refers to any improvement, one-time or continuous, large or small, in the same sense as the English word “improvement”.

Question 2

What is Kaikaku?

Answer 2

A rapid and radical change process used in Kaizen activities.

• uses larger investments, eg. reengineering of product or investments in more equipment
• can be called Kaizen Blitz
• based on process automation

Question 3

What are some benefits of Continuous Improvement?

Answer 3

Lower turnover, higher wages, higher ROI, higher profit per employee

Question 4

What are three main factors managers fear?

Answer 4

• poor quality
• increase of cost
• increase in lead times

Question 5

How do you find a problem?

Answer 5

define and understand the source and core of the problem

Question 6

What are the keys to the Japanese success?

Answer 6

• simple improvement methods
• worker involvement and respect
• teamwork

Question 7

What is Just-In-Time?

Answer 7

Delivering the right material, in the exact quantity, with perfect quality, in the right place just before it is needed.
-systematic application of a Lean methods to create a new way of doing things

Question 8

What are principles of JIT?

Answer 8

• minimizing inventory

- higher flexibility

Question 9

What are seven types of waste?

Answer 9

• overproduction- producing unnecessary products
• inventory
• transportation
• defects
• overprocessing- poor tool or product design
• motion
• waiting

Question 10

What is Lean Manufacturing?

Answer 10

the systematic elimination of waste

• improve the flow of information and materials
• lean is focused at cutting “fat” from activities

Question 11

What three philosophies support Lean Manufacturing?

Answer 11

• Kaizen
• JIT
• Jidoka (quality)

Question 12

What is Jidoka?

Answer 12

Lean manufacturing principle that ensures that quality is automatically built into a production process.

Question 13

What are the four steps that engage when defects occur?

Answer 13

1. detect the defect
2. stop production
3. fix the immediate condition
4. investigate the root cause and install countermeasures

Question 14

What are the 3 main time losses for equipment

Answer 14

• planned stops
• performance
• quality

Question 15

What are the six main causes that reduce valid operation time

Answer 15

• breakdowns
• setup and changeover
• idling and minor stops
• reduced speed
• defects and reworks
• starting losses , producing defects at being of machine start