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Question 1

What is lean manufacturing?

Answer 1

A systematic method for waste minimisation within a manufacturing system without sacrificing productivity.

Question 2

What does lean manufacturing attempt to make obvious?

Answer 2

What adds value, through reducing everything else that does not add value.

Question 4

What is the JIT inventory system?

Answer 4

A management strategy that aligns raw-material orders from suppliers directly with production schedules.

Question 5

What are the benefits of the JIT inventory strategy?

Answer 5

• Increases efficiency
• Decreases waste
• Reduces inventory costs.

Question 6

What does 5S stand for?

Answer 6

• Sort
• Set in order
• Shine
• Standardise
• Sustain.

Question 7

What is the first principle of lean?

Answer 7

Define value from the standpoint of the end customer.

Question 8

What is value stream mapping?

Answer 8

Identifying all steps in the value stream for each process, eliminating steps that do not create value.

Question 9

What is the goal of creating flow in lean manufacturing?

Answer 9

To make the value-creating steps occur in tight sequence for smooth delivery to the customer.

Question 10

What does the principle of establishing pull involve?

Answer 10

Letting customers pull value from the next upstream activity.

Question 11

What is the aim of seeking continuous improvement in lean?

Answer 11

To reach a state of perfection where value is created with no waste.

Question 12

What is Six Sigma?

Answer 12

A methodology developed by Motorola to improve product reliability and reduce variation in processes.

Question 13

What does the ‘Six’ in Six Sigma refer to?

Answer 13

The ideal goal of having six standard deviations fit within defined tolerance limits.

Question 14

What is a Six Sigma process expected to achieve?

Answer 14

99.99966% of all opportunities to produce a feature free of defects.

Question 15

What are the steps in the Six Sigma DMAIC approach?

Answer 15

• Define the problem and desired outcome
• Measure the ability of the process
• Analyse the data and identify root causes
• Improve or modify the process
• Control the process.

Question 16

What does DMADV stand for in Six Sigma?

Answer 16

• Define design standards
• Measure and identify critical characteristics
• Analyse data for sources of defects
• Design to eliminate defects
• Verify that the design meets requirements.

Question 19

What is included in upper management training for quality?

Answer 19

Broad coverage of all quality activities in the company, including quality policy, statistical methods, and QC/QA implementation.

Question 20

What additional elements are included in middle management training?

Answer 20

Some elements of upper management training, along with planning, supervision, cost control, and quality problem solving tools.

Question 21

What does quality management training focus on?

Answer 21

Training in business orientation and QA.

Question 22

What topics are covered in supervisor training?

Answer 22

Procedures, planning systems, sampling concepts, statistical methods, quality control charts, problem solving techniques, and quality improvement methods such as quality circles.

Question 23

What do operators learn in quality training?

Answer 23

Quality standards and specifications, standard operating procedures, testing and inspection methods, control charts, operator control, sampling methods, quality circles, quality improvement techniques, and teamwork.

Question 24

What is a Quality Circle?

Answer 24

A Quality Circle is a group of employees doing similar work under one supervisor who meet voluntarily each week to discuss quality problems, recommend solutions and (with management approval) implement them.

Also known as a quality improvement team.

Question 25

What are the focuses of Quality Circles?

Answer 25

Quality Circles focus on cost reduction, waste reduction, energy saving, safety, equipment, and procedures/work methods.

Question 26

What is the role of the Steering Committee in a Quality Circle?

Answer 26

The Steering Committee may or may not be present at a local level and is usually headed by a senior executive. They establish policy, plans, and direct the quality circle.

Question 27

What is the role of the Facilitator in a Quality Circle?

Answer 27

The Facilitator represents management’s commitment and promotes the quality circle, liaises between circles and management, organizes training programs, and keeps records.

Question 28

What is the role of the Circle Leader in a Quality Circle?

Answer 28

The Circle Leader is usually a team leader/line manager who fosters team thinking and facilitates time off during work schedules for meetings.

Question 29

What are the characteristics of Circle Members in a Quality Circle?

Answer 29

Membership must be voluntary, need not be permanent, and works best if members are from the same work area. The group should be small enough for effective teamwork but large enough to allow creativity.

Question 30

What is the role of Specialists in a Quality Circle?

Answer 30

Specialists may be invited to provide technical, mathematical, or engineering information to help solve a problem, such as healthcare professionals, statisticians, or quality managers.

Question 31

What are the organizational benefits of Quality Circles?

Answer 31

Organizational benefits include improved quality, improved safety, reduced cost, better communications, improvements to systems and processes, improved professional relations, improved environment, energy conservation, and reduced absenteeism.

Question 32

What are the potential psychological benefits of Quality Circles?

Answer 32

Psychological benefits involve the individual worker, value individual and collective thinking, enable creativity, and emphasize that problem-solving is not solely management's responsibility.