Lean final
pdf
keyboard_arrow_up
School
Lambton College *
*We aren’t endorsed by this school
Course
2193
Subject
Industrial Engineering
Date
Jun 22, 2024
Type
Pages
8
Uploaded by MateKangaroo2765
1.
Why is the purpose of the "5 why" exercise?
To determine the 5 critical to quality characteristics
To find 5 reasons why a feature occurred
To determine who, what, where, when and why something happened
To find the root cause of a failure by asking why enough times 2.
Put the following 5 whys answers in the correct order to answer the question: “Why did our team lose the game”
2 Our best forward player was absent
1 Our best forward player won the lottery
4 We didn’t score enough goals
3 We had a weak offense
3.
What type of waste could we uncover with a Value Stream Map (VSM)?
Material & Measurement
Space & Value
Motion & Transport
4.
Which of the following process mapping tools is most likely to highlight Defects and waiting. Spaghetti Diagram
FMEA
Swimlane Flowchart
SIPOC Chart
5.
What is the purpose of a SMED (single-minute exchange of dies) exercise?
To increase the number of dies that can be exchanged in 1 minute
To reduce set-up time
To reduce the number of dies used in a set-up
To improve set-up accuracy
6.
What is the purpose of the SORT step in 5S?
Arrange the tools in order of size or shape
Remove the tools or supplies that are not required, so only the necessary ones are left
Sort out the value from the non-value-added steps in the process
Order the supplied material by date received so, it can be used “first in first out”
7.
Kaizen means:
Process Control
Change for the better
Root Cause Analysis
The natural process drift of 1.5 sigma 8.
What is true for any lean process improvement?
Change should be approved by management
People will be naturally inclined to accept change
The benefit must be significant to justify the cost of the lean exercise
The process owners should be part of the solution
9.
A traditional Kaizen event often follows this sequence:
Cost Analysis, investment, realization, payback
Collect historical data study process documentation,
Conduct S-Why, affinity and C&S Exercises then update vsm state.
Train the team, analysis the current process, solution, improvements document and report out
10.
11.
Pick the best mistake-proofing option from this list
Eliminate or automate the high-risk operation
Provide better training for the employees involved
Add safety devices to prevent injury in case of operator error
Add an inspection operation to eliminate any mistake 12.
Select the 1 case where adding some from of mistake-proofing would not be
There is a risk of injury it the operator is no paying
Product can be included in a A task is repetitive and boring but needs to be done properly
13.
Why would we want to resolve the bottlenecks in a value stream
Because the bottleneck is responsible for defective product Removing the bottleneck improves FMEA
To improve the overall flow and shorten the total lead time
To increase the filling rate of bottles in production
14.
Sort the following options from best to least preferred according in the theory of constraints and lean practice
1 Design a balanced waste-free, pull process allowed a bottleneck
3 Improve the bottleneck process so it takes less time
2 Split the bottleneck process so that the work can be shared
4 Invest additional resources, labour or equipment, to support the bottleneck process
15.
What is the biggest waste that a pull system
Over Production and Inventory
Motion and transport
Space and non utilized resources
Waiting
16.
What supply-chain process works best with a Kanban” pull” production line?
Inventory is maximized on site and at the supplier to ensure 100% on-time delivery
Suppliers deliver 3-6 months’ worth of material as a time to reduce transport cost and allow for bulk pricing discounts Suppliers deliver Just-in-time based on current customer demand
Suppliers works to long term forecasts based on historical buying 17.
What is/are the primary reasons sample inspections are preferred 100% inspection?
Reduces the amount of data that needs to be analyzed
Demonstrates trust in the employees
Reduces inspection cost and time
100% inpreccion fins too many error and short
18.
Why process inspections preferred over product inspection?
Product inspection requires complex. Process inspection does not
Process inspection is less expensive than product inspection.
It isn’t product inspection is the only reliable way to ensure there are not defects.
Process inspection ensures process stays in control and proactively prevents bad product
19.
Which lean tool would likely show the most important factors for process monitoring to ensure a reliable process?
Spaghetti Diagram
Value stream Map
Your preview ends here
Eager to read complete document? Join bartleby learn and gain access to the full version
- Access to all documents
- Unlimited textbook solutions
- 24/7 expert homework help
Ishikawa/fishbone
Swimlane/flowchart
20.
Why is the main reason that visualization is included an part of the control phase?
Visualization provides visitors to the plans and chance to the what is being produced how often and how well
Visualization shows people what is expected as a part of the new, improved process in clear easy to follow information or instruction Visualization is an important part of the marketing campaign
Ir isn’t visualization must be done in the measure phase, to problem and clearly seen in preparation for the analyze phase
21.
Which of these are good examples of lean visualization?
Floor marking showing designated location for bins carts, ect
Product photographs
Clear such as the compacty must outside the holding
Morden graphics is PowerPoint slides.
22.
Match the visualization control to the improvement
Pull Production System - Kanban cards
5S - Shadow boards and foam cut-outs
Continuous Performance Improvement - Metric Charts and CTQ Targets
Improvements based on Spaghetti Diagram-Traffic Lane markings and directional signals for the movement of people
or
product.
23.
Select two goals of the Analyze phase.
i.
Determine the critical to the quality process inputs that hace an impact on process outputs
ii.
Generate the priority actions list for the “improve” phase of DMAIC
iii.
Create a problem statement
iv.
Calculate rolled Throughput Yield
1
y 2
24.
Select three purposes of chalk Circle.
i.
Observe both Value Add vs Non-Value Added Activity
ii.
Identify the objective of the project. iii.
Use statistical and problem solving tools
iv.
Understand process steps challenges and why the NVA are happening
v.
Look and analyze the 8 wastes during the process
1 4 y 5
25.
What questions should you answer when analyzing motion lean approach? Select 3 options
i.
Is batching necessary?
ii.
Is the workload excessive ( unbalanced compared to upstream process?
iii.
How much does the customer really need?
iv.
Are rools and resources located in optimal places?
v.
Is this report really necessary?
vi.
Who really need to know?
vii.
Are actions or steps to complete the process necessary?
2
4 y 7
26.
What does 5s stand for?
Sort, set, shine, standardize, sustain
Score, seek, set, shine, sustain
Sort, solve, shine, start, sustain
Select, degregate set, standardize, sustain
27.
Select three activities you would do in the SS "Shine" step
I.
Clean and tide workspace
II.
Sort out only what you need to do your work
III.
Notice malfunctions such as fluid leaks, vibration, and misalignment, and breakages
IV.
Check gauge or machine calibration
V.
Standardized tooling to make change-overs easier/faster
I. III, and IV
28.
Kanban can prevent over-production to control inventory
True
29.
Visual Management can serve as a visual tool to analyze a design of experiment
True
30.
Select four tools used in the Analyze phase
i.
5 Why
ii.
Chalk Circle
iii.
5S
iv.
Waste Identification
v.
Kaizen
vi.
FMEA
vii.
SMED
I, II, IV and VII
31.
What is the difference between a "pull" system and as "push" system?
They both triggers the supplier to replenish stock
In a "push" system, production control orders materials according to a forecast and in a "pull" system, the customer triggers the supplier to replenish stock In a "pull" system, production control orders materials according to a forecast and in a "push" system, the customer triggers the supplier to replenish stock They both order the material according to forecast
32.
What is true about the Control Phase?
“Systemize” the improvements, make the improvements part of the culture and permanent
Recognize where opportunities are and create an "inventory of potential re projects
Increase floor space capacity and employee satisfaction
Define and implement pilot projects
It is a very open-ended discovery process, often with no specific agenda problem needs solving
Create well-focused projects aligned with the win
Your preview ends here
Eager to read complete document? Join bartleby learn and gain access to the full version
- Access to all documents
- Unlimited textbook solutions
- 24/7 expert homework help
33.
The following picture represents the following diagram
Spaguetti Diagram 34.
The following picture represent a: 5 whys Example
35.
The following picture represent a: 5S
7 waste
Chalk Cicle
5 whys
Kanban
Single-minute exchange of dies
36.
A roadmap for problem solving and product/process improvement can of...
Flowchart
5S
DMAIC
Spagetti Diagram
37.
Select four potential wastes we can find in a substance flowchart
i. Turn-backs
ii. Excess inventory
iii. Delays
iv Overproduction
v Non-utilize resources
vi Extra costs
vii Extra-processing
II, IV, VI, VII