Lean Manufacturing Exam<br />NAME: _______________________________________<br />EXAM DATE: ______/______/______<br />For the following multiple choice questions, please indicate the best answer. Some answers may be correct but incomplete and not the best answer. Every correct response will earn the examine a point. Question 6, 8, 11, 13, 15, 16, 24, 27, 29, 30 and 31 are worth multiple points for correct responses. A calculator might be required.<br />
Value Stream Mapping looks at:
The people, material, and information flow in a value stream.
The material and information flows in a value stream.
The steps people take in designing and producing a product.
At the process level, for example in a single work-cell.
Calculate the Takt Time based on the following information:
Customer demand is 34,400 parts per month. The company works 5 days per week and on average 20 days per month. There are two, eight hour shifts. Lunch is 30 minutes per shift. Two, ten minute breaks are taken per shift.<br />The calculated Takt Time is:<br />
Forms a foundation for all other improvement activities.
Is a key to reducing inventory to improve lead time?
Cannot be used in an office or administrative area.
Match the 5S steps to their appropriate description (fill in the appropriate letter):
5S Launch_____<br />Sort_____<br />Set in Order_____<br />Shine_____<br />Standardize_____<br />Sustain_____<br />
identify best locations for items, relocate out of place items, set inventory height and size limits, focus on safety, install temporary location indicators.
Involves forming a core implementation team, identifying a project using a team charter, performing a Workplace Scan and display.
Create rules such as holding rules and responsibilities; locations, number and position of items; cleaning schedules and procedures; storage and retrieval systems; visuals controls to share information and highlight conditions.
Look at items in work area, red tag, keep what’s needed/eliminate what’s not, and reduce number of items to what’s required.
Develop awareness and skills, make 5S part of daily work, get commitment from top management to make time for 5S, 5S audits, and ongoing 5S communications.
Identify sources of containment; determine targets and assignments for cleanliness; make everything like “new”, check if replacement or repair is necessary; replace wires, hoses, tubes, etc.
5S efforts often fail to be sustained because:
Managers implement 5S but employees don’t do the work to keep it up.
Check all that apply to goals of Mistake Proofing
_____ Eliminate problem people<br />_____ Make product with zero defects<br />_____Remove process variables reducing opportunities for mistakes<br />_____ Make it impossible to make mistakes<br />_____ Repair defective product<br />_____ Make things right with the customer including recalls and repairs<br />_____ Immediately detect defects if they occur<br />_____ To catch and fix human mistakes<br />
Please match the method with the appropriate description or example of mistake proofing:
_____Contact/Physical Contact Device<br />_____Performance Step/Motion-Step Device<br />_____Fixed-Value Device<br />_____Operator Initiated Controls/Doing It Right Device<br />
A parts feeder automatically counts out the nine bolts required for assembly when the operator presses a lever. The part assembled with the nine bolts isn’t allowed to leave the station unless all nine bolts are installed.
Proximity switches mounted on sides of a blank plate trip when the blank is properly positioned allowing the machine to start. If switches are not tripped, the machine won’t start.
Color-coding one side of a part so it is assembled with the correct side up.
A photoelectric switch is connected to a timer; if movement of the part doesn’t occur when it should at the right step in the process (for example, it is forgotten by the operator), the switch signals the machine to stop.
A major barrier to inventory reduction and batch size reduction is.
_____ Action taken addresses the system failure that allowed one operator to go untrained in the first place<br />_____ Action taken to prevent occurrences of a problem which has never occurred such not allowing smoking in the building to prevent the first time occurrence of a fire in the building <br /> <br />_____ Action taken is to “retrain the operator to follow the proper procedures” in response to a problem that occurred<br />