Lean Bronze Certification Exam Study
Guide
Continuous Flow - answerhigh production volume, highly standardized commodity products
Jidoka - answerautomatically stopping the process when something is wrong and then fixing the
problems on the line itself as they occur
Autonomous Maintenance - ans...
Continuous Flow - answer✔high production volume, highly standardized commodity products
Jidoka - answer✔automatically stopping the process when something is wrong and then fixing the
problems on the line itself as they occur
Autonomous Maintenance - answer✔An improvement process focused on improving the condition of a
machine and then identifying, standardizing and training on operator maintenance tasks
Andon light - answer✔Signal for a need or problem with equipment or process. Example of visual
management
A3 document - answer✔This helps to capture and share knowledge in a structured way. Its commonly
used as a problem-solving tool. This should also be used as a coaching tool between a coach and a
learner. Reference Managing to Learn by John Shook.
Empowered Employees - answer✔The heart and soul of a lean organization according to Masaaki Imai
(Gemba Kaizen)
Sort - answer✔The first step of 5S
Highland Park - answer✔The Ford Factory that housed the Model T production
consensus - answer✔A general agreement by team members. Not everyone may fully agree with the
idea but no one is openly opposed and they can "live with it".
Goal of Hoshin Kanri - answer✔To align the tactical actions and improvements to the strategic objectives
of the business. This is a layered process which should be flowed from the higher level group and then
down to the next level.
cross-functional team - answer✔Employees from different areas coming together to complete a task or
solve a problem
Sequential pull system - answer✔A type of system is used when product variation is high and it doesn't
make sense to keep an inventory of each product. With this type of system, we control the overall
inventory in the system by only releasing when a trigger is created.
interchangeable parts - answer✔According to Dennis (Lean Production Simplified), the greatest enabler
of mass production
Standardized Work & Jidoka - answer✔"Separating Man from Machine" describes the ability to have
one operator run multiple machines. This is enabled by
Standardized Work - answer✔Route of the operator is clear and documented
Little's law - answer✔The relationship between work in process (WIP), throughput and lead time
PQCDSM - answer✔A core set of goals and measures that we are tracking on a daily basis.
Value Stream - answer✔The entire sequence of work required to bring a product from raw material to
delivery
Theory of Constraints - answer✔"The Goal" by Goldratt popularized this concept which focuses on
bottleneck management
Joseph Juran - answer✔This person introduced the Pareto principle as it applies to quality control
PERT Calculations - answer✔(Optimistic + 4 x Most Likely + Pessimistic) / 6
PERT - answer✔A scheduling and program planning method
SMART goal - answer✔Specific, Measurable, Achievable, Realistic and Timely
7 types of Muda - answer✔Transportation, Inventory, Motion, Waiting, Overprocessing,
Overproduction, and Defects
waste - answer✔The fundamental concept behind lean manufacturing is the elimination of __________
WIP calculaton - answer✔Leadtime x Throughput
set in order - answer✔a place for everything and everything in its place
NUMMI - answer✔The name of the joint venture between GM and Toyota
Concentration diagrams - answer✔"Measles Charts" are another way to describe what tool
Taiichi Ohno - answer✔Who is most often referred to as the godfather of lean manufacturing
Reduction of changeover times - answer✔SMED (Single Minute Exchange of Dies) focuses on
Value Stream Mapping - answer✔Learning to See by Shook and Rother is widely regarded as the
foundation of what
JIT and Jidoka - answer✔The pillars of the Toyota Production System (TPS)
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