WorksheetsLEAN Foundation - English Ver.
Total questions: 20
Worksheet time: 10mins
This shows the definition and objectives of Visual management. Choose one INCORRECT item from the list.
Visual Management provides the immediate visible indication of performance and flow of the operation and its abnormalities in order to...
Generate transparency
Standardize workplaces
Facilitate involvement and learning, also across departments and functions
Provide additional effort to update inputs
Engage all employees in problem solving
This is the Overview of one HPS element. Select right element among examples.
Visual Management
5S
Autonomous Maintenance
Standardized Work
Check the sentence and response properly
Visual Standards are a means of communication which allow anyone entering a workplace to quickly diagnose how things are done in that area
True
False
The below picture shows how to identify the Work. Select right match of 3 blanks in sequence
A. Output
B. Rework
C. Opportunity
A. Operation
B. Management process
C. Rework
A. Value Added Work
B. Non-Value Added Work
C. Waste
A. Value Added Work
B. Non-Value Added Work
C. Problem
A. Value Added Work
B. Value-less Work
C. Problem
These are time criteria for applying Standardized Work. Choose the right Time term combination among examples.
A. Takt Time
B. Lead Time
A. Takt Time
B. Cycle Time
A. Cycle Time
B. Takt Time
A. Cycle Time
B. Set up Time
A. Lead Time
B. Set up Time
This is about the benefit of 5S as described. Select one INCORRECT answer among examples described.
The 5S system sounds so simple that people often dismiss the importance of it, however, the fact remains that a neat and clean factory
... has higher productivity!
... produces fewer defects!
… brings higher workload!
... is a much safer place to work!
... meets deadlines better!
What’s interpretation of the picture below? Select correct answer among examples described.
It’s the goal of Pull system to improve process
We shall work on improvement our workplace to decrease Non-Value Added Work and eliminate Waste.
Process time becomes shorter by improvement, but overall time goes with same by CI activity
Waste must be eliminated to zero by all means, in order to achieve our Goal
Which description is INCORRECT about the interpretation of the picture?
At Push, production signal goes to the first process then start dealing with inventory.
At Pull, production signal goes to the last process then start dealing with inventory
Pull shows improved way for meeting customer delivery and ECSL.
Inventory can be managed with fluctuating less by Pull.
In case production order is unstable with many unexpected change and issue, Push shall be applied to meet customer delivery.
Which item among the five S’ is the picture below demonstrating improvement?
Sort
Set In Order
Shine
Standardize
Sustain
The below shows the Required pre-conditions before introducing a PULL System. Choose one INCORRECT phrase among examples
5S & Visual management implemented on the shop floor to manage visually material flow (raw material, packs, semi fished, finished goods, …)
Differences in usage and unit numbers of orders
Transport cycles that are as short and uniform as possible (takted supply by logistics)
Small batch sizes through change over time reduction & Autonomous Maintenance (low stocks due to stable replacement time for the upstream process)
Various forms of packaging for the recipient (large and small practical packaging units as possible)
The Pull System should give a Visual Indicator that the down stream process needs more material, either by a visible “vacancy” that needs to be filled, or this card that indicates what action(s) now needs to be taken. What’s the name of this card?
Takt
Red Tag
Pull
Kanban
ORCA
Which item among the five S’ is the picture below demonstrating improvement?
Sort
Set In Order
Shine
Standardize
Sustain
Which item is farthest from Visual Management applied to?
Material Flow
Communication
Site Areas and Equipment
Performance
Organizational Strength
The below picture is about Takt time and Cycle time. Select 2 INCORRECT answers among examples explaining the visual chart.
At Before Standard work case, Seal #1, #2, Box process have idle time during operation.
After Standard work applied, all processes are balanced the workload and have no overburden concern.
Label has longest cycle time meaning highest productivity at the process.
Total 9 processes are covered by 9 operators.
After Standard work, Seal #1, #2, Box process have to work with increased cycle time.
This sheet as example shows definition & visualization of the work process steps by standardized way. It drives operation consistently by standard. Also it’s utilized to train new employee to the process, it helps operators’ sustaining operation skill, and it works as a basis of continuous improvement gradually. Pick up the right name of this sheet.
Operation Process Sheet
Job Instruction Sheet
Operation Instruction Sheet
Work Process Manual
AM Daily Check Sheet
Those are description of Objectives and Benefits about Pull System. Select one INCORRECT sentence.
The objective a Pull System is to provide product to the Customer aligning with their required Takt Time, while keeping our inventory and costs down. Along with our own cost benefits, we are able to impress our Customers, which not only secures existing business, but has the potential to win additional business.
The Pull System also provides benefits to our Shop Floor. Our people no longer have to waste time and effort by making something the Customer is not ready for, or not willing to pay for. Our People will also get to experience a steady, consistent pace of work, aligned with the Takt Time of the Customer.
The Pull System even provides benefits to reduce the Takt time. Improved signaling system to operation will contribute to shorten Takt time and it leads to the improved service level to Customer delivery.
The goal is to have low-waste, Just In Time production by reaching the 5R’s (not to be confused with 5S): Right Part, Right Quality, Right Time, Right Quantity, Right Price.
Those are description of Kanban “Rules”. Identify one INCORRECT sentence
In order for the successful use of this approach, the following “Kanban rules” should be followed :
The KANBAN pulls the part to be used from the process upstream of it.
The upstream process produces exactly the right quantity in the correct sequence of KANBANs arriving
KANBAN (cards) must be utilized covering all process boundaries.
KANBAN (cards) must not be collected in one process
Number of KANBAN (cards) in the system must be checked on a regular basis
There are 7 wastes with initials of TIMWOOD. Choose the right definition of 7 wastes type.
T-Transportation
I-Inventory
M-Motion
W-Waiting
O-Overproduction
O-Overprocess
D-Default
T-Transformation
I-Inventory
M-Motion
W-Waiting
O-Overproduction
O-Overprocess
D-Defect
T-Transportation
I-Inventory
M-Motion
W-Waiting
O-Overproduction
O-Overprocess
D-Defect
T-Transportation
I-Information
M-Motion
W-Waiting
O-Overprogram
O-Overprocess
D-Default
T-Transformation
I-Information
M-Motion
W-Waiting
O-Overprogram
O-Overprocess
D-Defect
There are 5 ‘S’ words in 5S activities as HPS element. Choose the Correct one listed by right sequence.
S – Sort
S – Shrink
S – Sanitize
S – Standardize
S – Sustain
S – Sort
S – Set in Order
S – Shine
S – Standardize
S – Suspend
S – Seiri
S – Seiton
S – Seisou
S – Seiketsu
S – Setsuyaku
S – Sort
S – Set in Order
S – Shine
S – Standardize
S – Sustain
This shows the linkage of it with Standard Processes and Gemba Walks. What’s the correct item inside the blank?
Visual Management
5S
Autonomous Maintenance
Standardized Work
