Lean Belt Certification
What does "CBA" stand for and what is it?
"Cost Benefit Analysis" It is used to determine options that provide the best "ROI" which means return on investment
What does "COPQ" stand for?
"Cost of Poor Quality"
What does "CTQ" stand for?
"Critical to Quality"
What does Gage R&R stand for?
"Gage Repeat-ability and Reproducibility" which is a statistical tool that measures the amount of variation in the measurement system arising from the measurement device and the people taking the measurement.
What does "Gemba" mean?
"Go to" i.e go to the place and see how the work is done
What does JES stand for and what does it consist of?
"Job Element Sheets" - Consists of 4 key factors What, How, Why, and Consequences - What is the work task that is required to be carried out? - How is the task that is to be carried out? - Why this is required to be carried out? - Consequences (Potential) if the task is not carried out in this particular manner (Safety, Defect, etc.)
What does "Kanban" mean and who developed it
"Kanban is a manufacturing system in which the supply of components is regulated through the use of an instruction card sent along the production line" and it was developed by Taiichi Ohno
What does "KPI" Stand for?
"Key Performance Indicator"
What does "OEE" stand for
"Overall Equipment Effectiveness" Multiply %'s (Availability, Quality, Efficiency)
What does "TPM" stand for
"Total Productive Maintenance"
What does "VOC" stand for?
"Voice of The Customer"
how do you calculate how many Operators you need per process?
(Cycle Time) / (Takt Time)
What are the 7 kinds of waste
(use acronyms Dotwimp or Downtime w/o the n) 1.) Defects 2.) Overproduction 3.) Transportation 4.) Waiting 5.) Inventory 6.) Motion 7.) Excess Processing (There are sometimes 8 which includes the n in Downtime which is Non-utilized Employees
What does DMAIC stand for?
1. Define 2. Measure 3. Analyze 4. Improve 5. Control
What are the steps to building a Business Plan?
1. Executive Summary. Your executive summary is a snapshot of your business plan as a whole and touches on your company profile and goals. ... 2. Company Description. ... 3. Market Analysis. ... 4. Organization & Management. ... 5. Service or Product Line. ... 6. Marketing & Sales. ... 7. Funding Request. ... 8. Financial Projections...
Name 3 types of VSM's
1.) Concept to Launch 2.) Raw Material to Finished Product 3.) Order to Cash
Jidoka Steps
1.) Discover an Abnormality 2.) Stop the Process 3.) Fix the Immediate Problem 4.) Investigate and solve the Root Cause
What are the 4 M's?
1.) Man 2.) Machine 3.) Material 4.) Method
what are the 5s's?
1.) Sort 2.) Set in order 3.) Shine 4.) Standardize 5.) Sustain
What are the 14 elements to a Value-added Time Report Log
1.List all of the steps in a process from beginning to end. 2. Create a diagram with a box for every step, in sequence. 3.Calculate the time currently required to complete each step of the process, and add that time to the box - See FIGURE 1 below. 4. Add the time in each box to yield the Total Cycle Time. 5. Identify those steps that do not add value to the process. Non value-added operations include: inspection, test, rework, set-up, inventory buffers, product movement other than customer delivery - any activity that does not improve the form, fit, or function of the product on the first pass through the process. 6. Move the boxes representing non-value-added processes to the right of the value-adding steps -see FIGURE 2 below. 7. Add the time in each of the non-value-added processes to yield the Non-Value-Added Cycle Time. This is the waste that could be eliminated if only value-added steps were performed. 8. Add the time in each of the value-added process to yield the Value-Added Cycle Time. 9. Calculate the percentage of the Total Cycle Time that is a function of Non-Value-Added operations. You may wish to construct a pie chart to communicate the analysis - see FIGURE 3 below. 10. Identify the target process configuration using benchmarking and best-in-class analysis. 11. Diagram the target process and determine the Total Target Cycle Time - see FIGURE 4 below. 12. Analyze the Non-Value-Added steps to identify actions to reduce or eliminate these operations. 13. Analyze the Value-Added steps to identify improvement opportunities and implement actions to reduce the cycle time. 14. Diagram the improved process, compare to the target process, and identify gaps for further improvement actions on an ongoing basis until the target is achieved.
A ______________ is a graphical representation of a process showing the relationships among process steps and includes symbols such as a diamond, rectangle, and circle? a. Process map b. Pareto diagram c. Schematic d. Why-why
A
A range chart displays the variation or spread of a process? a. True b. False
A
Cp and Cpk represent long-term capability, while Pp and Ppk represent short-term capability? (hint: short-term and long-term capability heading) a. True b. False
A
How are similar products usually grouped when value stream mapping? A. By having a commonality of 70% or more B. By having a commonality of 50% or more C. By having similar profiles D. By size E. By weight
A
If p = .096, and n = 950, what is the LCLnp and UCLnp? a. 63.96 and 118.43 b. 27.24 and 91.23 c. 91.28 and 118.43 d. None of the above
A
Nine purchase orders are to be processed in 780 minutes. The takt time would be? a. 87 b. 80 c. 85 d. 88
A
The area under the standard normal curve between +1.19 standard deviations and +2.14 standard deviations is __________? a. .1008 b. . 1040 c. .1254 d. .1170
A
True or False. The p chart is used when the sample size varies?
A
What does MSA stand for? a. Measurement system analysis b. Measurement system attribute c. Measurement system appraiser d. None of the above
A
What is used when there are internal problems with the value stream? A. safety inventory B. buffer inventory C. customer inventory D. none of these
A
What measurement scale is this an example of: Dollars? a. Ratio b. Nominal c. Ordinal d. Interval
A
What type of error occurs when the null hypothesis is rejected when it is true? A. Type I B. Type II C. Type III D. Type IV
A
When drawing a production matrix, where are the products listed? A. on the top of the spreadsheet B. on the far right of the spreadsheet C. on the far left of the spreadsheet D. on the bottom of the spreadsheet E. they are not listed on the spreadsheet
A
What is "Kaizen"
A Japanese business philosophy of continuous improvement of working practices, personal efficiency, etc.
According to the attribute capability analysis, what is the correct defects per million? a. 235,308 b. 150,000 c. 678,521 d. 86,4540
B
According to the diagram below, what is the cumulative percentage of the 3rd most occurring defect? a. 54% b. 70% c. 91% d. None of these ( can't upload chart)
B
An air gap exists between fluids in a bottle and the cap of the bottle. At a firm producing olive oil, the gap is critical to the shelf life of their product. If the recent information reveals that the average gap is 9.46 mm with a standard deviation of 0.233, the percentage of product with the specification limit of 9.00 mm is _________? a. .0444 b. .0244 c. 8621 d. .1379
B
Continuous or variables data result from characteristics that are counted? a. True b. False
B
Fifty pairs of shoes are to be sold in 500 days. What would be the takt time for producing these shoes? a. .1 b. 10 c. 100 d. 1
B
Suppose .12 grams of insect parts is found in 50 kilograms of product, what is the Parts per million (PPM)? a. .24 b. 2.4 c. 12 d. none of these
B
What does SIPOC stand for? a. Suppliers Investment Procedures Organize Customers b. Suppliers Inputs Process Outputs Customers c. System Inputs Programs Outputs Customers d. System Inputs Process Outputs Customers
B
Where does the supplier box belong on a value stream map? A. top right corner of paper B. top left corner of paper C. top and middle of paper D. top right or top left corner of paper E. none of these
B
______________ sampling is the process of selecting units for a sample in such a manner that all combinations of units under consideration have an equal or ascertainable chance of being selected for the sample? a. Stratified b. Random c. Cluster d. Systematic
B
If there are 52 cards in a deck, 4 kings and 13 diamonds. What is the probability of selecting a card that is both a king and a diamond? Hint: P(K U and this is a nonmutually exclusive event) a. .3269 b. .7100 c. .3077 d. .9473
C
If there are 8 bolts that are US spec and 6 bolts that are short, what is the probability of selecting either a US spec bolt or a short bolt? (hint: P(US U Short)) a. .5714 b. .1234 c. .9999 d. .0714
C
The range of the following numbers: 34, 35, 36, 34, 32, 34, 45, 46, 45, 43, 44, 43, 34, 30, 48, 38, 38, 40, 34 is? a. 38 b. 30 c. 18 d. 8
C
The takt time is 11 minutes and the cycle time for a particular step is 40 minutes, how many people are required? a. 3.6 b. 3 c. 4 d. 4.6
C
What does FMEA stand for? a. Factor mode and effects analysis b. Forming mode and effects analysis c. Failure mode and effects analysis d. Failure mode and external analysis
C
What is standardized work?
Consists of the three elements 1.) Takt time, which is the rate at which products must be made in a process to meet customer demand 2.) The precise sequence in which an operator performs tasks within takt time 3.) The standard inventory, including units in machines, required to keep the process operating smoothly
A ________ chart is a type of chart used in process/project planning and control to display planned work and finished work in relation to time? a. Control b. Mean c. Range d. Gantt
D
A batch process produces cigars with a specification on the dextrose equivalent (DE) of 7.00 to 7.10. The DEs are normally distributed, and a control chart shows the process is stable. The standard deviation of the process is .032. The DEs from a random sample of 50 batches have a sample mean of 5.02. The Cp is and is the process "not capable" or "capable"? a. .19, capable b. .52, capable c. 19, not capable d. .52, not capable
D
How many operators are required if the takt time is 60 seconds and operation 1 takes 55 seconds, operation 2 takes 75 seconds, operation 3 takes 86 seconds, operation 4 takes 95 seconds? Do NOT round up or down. A. 3 B. 4 C. 5 D. 6 E. none of these
D
What could be impacted by GD&T in regards to the 7 wastes of a lean organization? A. motion B. conveyance C. correction D. overprocessing
D
What is the sample standard deviation of the following data set: 10, 14, 17, 20? a. 4 b. 18.25 c. 18 d. 4.27
D
Which of the following is true? (Best answer) A. A VSM is often difficult to follow for shop floor personnel. B. A VSM is only a preliminary tool for restructuring labor and management. C. A VSM is a tool to improve product quality. D. A VSM enables all stakeholders of an organization from the ground up to easily visualize and understand the process.
D
Who is the person responsible for monitoring the meetings and takes the minutes for a team working on a lean six sigma project? A. team facilitator B. team leader C. team champion D. time keeper & scribe
D
What are the four common measures of process performance?
DPU, DPMO, PPM and RTY. Four common measures of process performance are Defects Per Unit (DPU), Defects per Million Opportunities (DPMO), Parts per Million Defective (PPM), First Time Yield (FTY) and the Rolled Throughput Yield (RTY)
How should you check a current state value stream map? A. Ask top management how product flows B. Ask shop floor personnel how product flows C. The "team" checks the map D. Use existing diagrams of flow E. Follow the value stream on the shop floor
E
What does "FMEA" stand for and what does it mean?
Failure modes and effects analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service. "Failure modes" means the ways, or modes, in which something might fail. Failures are any errors or defects, especially ones that affect the customer, and can be potential or actual.
What is Lead Time?
Formula? Lead time = (Cycle Time)*(WIP) or (WIP)/(Throughput) The lead time is the sum of the supply delay and the reordering delay. A lead time is the latency between the initiation and execution of a process. For example, the lead time between the placement of an order and delivery of a new car from a manufacturer may be anywhere from 2 weeks to 6 months.
Poka-Yoke
Mistake-Proofing
What does "IRR" Stand for and what is it?
Internal rate of return (IRR) is a metric used in capital budgeting measuring the profitability of potential investments. Internal rate of return is a discount rate that makes the net present value (NPV) of all cash flows from a particular project equal to zero.
What could Inventory consist of
Inventories consist of raw material, work-in-process and finished goods which are held by a business in ordinary course of business, either for sale or for the purpose of using them in the process of producing goods and services. Raw material is a type of inventory which acts as the basic constituent of a product. Work in process is a type of inventory that is in the process of production. Finished goods is a type of inventory which comes into existence after the production process in complete. When inventory is purchased, the cost of inventory includes the purchase price, delivery costs, excise and custom duties etc. less any discount that is obtained.
Muda, Mura, and Muri
Muda - the 8 wastes Mura - Unevenness Muri - Overburden
What does NPV stand for and what does it mean
Net Present Value (NPV) is the difference between the present value of cash inflows and the present value of cash outflows. NPV is used in capital budgeting to analyze the profitability of a projected investment or project.
Which of the seven kinds of waste is the worst?
Over-Production
what is the formula to calculate Pitch?
Pitch = (Takt Time)*(Pitch Batch Size)
What is ROI?
ROI is usually expressed as a percentage and is typically used for personal financial decisions, to compare a company's profitability or to compare the efficiency of different investments. The return on investment formula is: ROI = (Net Profit / Cost of Investment) x 100.
What does "SIPOC" stand for and what does it have to do with process mapping?
SIPOC (suppliers, inputs, process, outputs, and customers) is a visual tool for documenting a business process from beginning to end. SIPOC (pronounced sigh-pock) diagrams are also referred to as high level process maps because they do not contain much detail.
What is a Master Document?
The Master Document feature in Word 2013 allows you to collect and coordinate individual documents — called subdocuments — and cobble them all into one, large document.
What is the 80:20 Pareto Rule?
The rule discovered by Alfred Pareto that essentially applies to all of life is that 20% of your problems make up 80% of your costs.
what is the definition for Cycle time?
The total time from the beginning to the end of your process, as defined by you and your customer. Cycle time includes process time, during which a unit is acted upon to bring it closer to an output, and delay time, during which a unit of work is spent waiting to take the next action. also equal to the sum of takt times needed to complete a product
What does the Phrase "5 Whys" refer to?
This is referring to the attempt to find the root of a problem, you start with the first problem you find, and then ask why that happened, and then proceed to do this 4 or more times in order to make a long term solution
TPS
Toyota Production System
What is an "A3" AKA "SPS"
a structured problem solving and continuous improvement approach, first employed at Toyota and typically used by lean manufacturing practitioners. (SPS stands for Systematic Problem Solving)
What is Visual Management?
a tool using visual cues to make succinct, accurate information within a workplace available at all times to those who need to know it.
What does "Heijunka" mean?
it is a Japanese word that means "Leveling"
What is Takt Time?
the rate at which products must be made in a process to meet customer demand Formula : (Customer Demand) / (Available Time to produce)