Lean Manufacturing and 5S Methodology Quiz
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Lean Manufacturing and 5S Methodology Quiz

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Questions and Answers

What does 'N' stand for in the acronym DOWNTIME related to lean wastes?

  • Non-compliance
  • Non-conformance
  • Neglected resources
  • Non-utilized talent (correct)

    • Which of the following is a key characteristic of lean 'Production Precision'?

  • Anticipated usage
  • Management by firefighting
  • Excessive inventory
  • Small lots and low inventories (correct)

    • Which waste is characterized by unnecessary movements of products and materials?

  • Defects
  • Overprocessing
  • Transportation (correct)
  • Waiting

    • What is the primary focus of lean thinking concerning inventory?

    <p>Reducing waste through lower inventories</p> Signup and view all the answers

    Which waste is often connected to excessive movement within a workspace?

    <p>Motion</p> Signup and view all the answers

    What management approach is associated with high inventories and large production lots?

    <p>Push management</p> Signup and view all the answers

    Which of the following best describes 'Waiting' as a lean waste?

    <p>Delays in workflow</p> Signup and view all the answers

    How can a business best address the waste of 'Defects'?

    <p>Through continuous improvement processes</p> Signup and view all the answers

    What is a key component of Overall Equipment Effectiveness (OEE)?

    <p>Quality</p> Signup and view all the answers

    In a lean manufacturing environment, which formula most accurately defines profit?

    <p>Profit = (price-cost) * volume</p> Signup and view all the answers

    Which type of maintenance failure is categorized as 'self-induced'?

    <p>Failures due to human error or negligence</p> Signup and view all the answers

    What does the 'Pull' technique imply in shop floor supply management?

    <p>Items are produced based on actual demand</p> Signup and view all the answers

    Which of the following practices is most beneficial in avoiding maintenance failures?

    <p>Self-induced failures</p> Signup and view all the answers

    Why is it important for teams participating in 5S audits to receive recognition?

    <p>To reinforce positive behavior and improvement</p> Signup and view all the answers

    Which of the following statements is TRUE regarding Operations and Maintenance teams?

    <p>They work collaboratively to enhance OEE.</p> Signup and view all the answers

    What does the term 'standardize' imply in the 5S methodology?

    <p>Uniformity in how tools and records are maintained and organized is essential.</p> Signup and view all the answers

    What is the formula for calculating Overall Equipment Effectiveness (OEE)?

    <p>Availability imes Performance imes Quality</p> Signup and view all the answers

    If a machining center has an availability of 88.0%, a performance of 93.0%, and a quality rate of 95.0%, what is the OEE?

    <p>77.7%</p> Signup and view all the answers

    How is TEEP calculated using OEE?

    <p>TEEP = Utilization imes OEE</p> Signup and view all the answers

    What is the purpose of measuring TEEP as opposed to OEE?

    <p>TEEP measures effectiveness against 24 hours per day, 365 days per year.</p> Signup and view all the answers

    What is the result of the Utilization calculation if the machining center operates 20 hours a day for 300 days in a year?

    <p>68.5%</p> Signup and view all the answers

    What is the impact of unscheduled downtime on the Availability of equipment?

    <p>It decreases the availability percentage.</p> Signup and view all the answers

    In the case study example, what was the scheduled maintenance time per shift for the equipment?

    <p>45 minutes</p> Signup and view all the answers

    If the designed production rate is 20 units and the actual production is 18 units, how would you calculate Asset Performance?

    <p>Actual production rate / Designed production rate</p> Signup and view all the answers

    Study Notes

    5S Methodology

    • 5S is a methodology used to create a clean, organized, and efficient workplace
    • Five Steps:
      • Sort (Seiri)
      • Set In Order (Seiton)
      • Shine (Seiso)
      • Standardize (Seiketsu)
      • Sustain (Shitsuke)

    Lean Manufacturing

    • Pull System refers to a production system where products are made only when needed
    • Push System refers to a system where products are made based on anticipations, leading to potential excess production
    • Inventory is a major waste in Lean Manufacturing
    • Production precision implies small lots, low inventories, and reduced waste
    • Production approximation implies large lots, high inventories, and potential waste

    7 Wastes of Lean

    • The 7 wastes are: Overproduction, inventory, waiting, transportation, motion, defects and over-processing.
    • These wastes can lead to reduced operational efficiency and increased costs

    8 Wastes

    • The 8 Wastes can be remembered using the acronym "DOWNTIME"
    • The 8 wastes are: Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, and Extra-processing.

    OEE (Overall Equipment Effectiveness)

    • Measurement of effective use of production equipment
    • Formula: Availability * Performance * Quality
    • A world-class facility should aim for a utilization rate above 98%
    • Key Components:
      • Availability: The percentage of time equipment is available for production, calculated by dividing uptime by the sum of uptime and downtime
      • Performance: Measures how efficiently equipment operates, calculated by dividing actual production rate by the designed (best) production rate
      • Quality: Measures the percentage of good units produced from total units produced

    TEEP (Total Equipment Effectiveness Performance)

    • Measure of effectiveness based on 24 hours per day, 365 days per year operation
    • Formula: Utilization * Availability * Performance * Quality
    • Utilization is calculated by dividing the total time the equipment is operating by the total time available

    Downtime Types

    • Idle Time: Includes situations where the equipment is not in use due to factors like no demand, no feedstock, or not scheduled for production

    • Scheduled Downtime: Refers to planned downtime for maintenance, repairs, and other scheduled events

    • Unscheduled Downtime: Includes unplanned downtime due to unexpected repairs, failures, or external interruptions.

    • Case Study 1

      • Equipment availability is calculated by subtracting the total downtime from the total scheduled time and dividing by the total scheduled time.

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    Description

    Test your knowledge on Lean Manufacturing principles, including the 5S methodology and the various types of waste in production. This quiz covers essential concepts such as sorting, organizing, and sustaining efficiency in the workplace. Challenge yourself to recognize the differences between push and pull systems and the impacts of waste on operational efficiency.

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