Question

What are the principles of Kaizen?

5.      Explain the 9 general steps in a Kaizen event.

6.      What are techniques to determine the voice of the customer?

7.      What is a SIPOC? Describe each element of a SIPOC

8.      What are the elements of a Swimlane value stream map? What should be added to each task box or note beyond the description of the task? What are the key metrics at the bottom of the Swimlane Value stream Map?

9.      What is Lean? What are the key elements of the lean transformation methodology?

10.    What is the lean concept of waste? What are the 8 forms of waste as defined in lean and be able to give an example of each.

11.    In lean terms – what is ‘lead time’?

12.    Explain Little’s Law. Be able to calculate lead time.

13.    What is WIP or work in process?

14.    Explain what process cycle efficiency means. Be able to calculate a PCE (process cycle efficiency).

15.    What is a pull system? What is the value of a pull system versus the typical way that work is distributed?

16.    What are the keys to creating an effective pull system?

17.    What is Kanban? What are the 3 rules of Kanban?

18.    What is the Lean 20/80 rule?

19.    Explain how both SOAP and REST based web services work and differences between them. Contrast these web services with messaging queuing middleware like IBM MQ or Java Messaging Services

20.    Be able to explain the value of a loosely coupled software architecture

21.    Explain what an architectural quantum is and how it applies to loose and tight coupling architectures

22.    What is an unstructured monolith architecture and why is it difficult to change?

23.    Explain the value of a layered monolith or an unstructured monolith.

24.    Explain how an ESB and services oriented architecture work and what value they bring to the services used in the application

25.    Explain what a microservice architecture is and how it enables loose coupling and the possibility of adding features on a daily basis to a major application.

Answer 1

Kaizen is a japanese philosophy which inlcudes all the employees from the top management to the bottomline workers contribute to the continoul improvement of the functions without recording it as a project.

Kai – Change ( nothing remains the same )
• Zen – A System that is continually growing /
evolving beneficially
Kaizen is a system of creating evolutionary beneficial change in what ever we do and makes:

.Make things Easier
• Remove Redundancy and Drudgery
• Make things Safer
• Make efforts more productive
• Improve performance of outputs
• Save time
• Save Cost

5. The steps are

1. Empower your employees to generate and share their ideas for improvement.
2. Develop a system for identifying the best ideas.
3. Implement the best ideas as soon as possible to encourage employees to participate.
4. Develop a rewards and recognition system for the best ideas based results.

6. The voice of customer :

1. Find out all the customer and the customer needs.

2. Match the customer needs with the features of the product.

3.Match the features with the process features.

4.Features with optimazation charts and then with control charts.

7.ans

9ans. Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity. Lean manufacturing is based on a number of specific principles, such as Kaizen, or continuous improvement. The key concepts are

a. specify value

b. map value stream

c.establish flow

d.implement pull

e. Work for perfection.

10ans.

The 8 Wastes of Lean Production – DOWN TIME

•Defects, which require effort and cost for corrections.

•Over-production of a product;

•Waiting, whether it is people waiting or idle equipment

•Non-utilization of resources

•Unnecessary Transportation;

•Excess Inventory;

•Unnecessary Motion of people, equipment or machinery;

•Excess-processing or putting more time into a product than a customer needs, such as designs that require high-tech machinery for unnecessary features;  

11 ans.lead time is the time that elapses between the realisation of the need for an item until fulfillment of the need. Lead time has two parts basically : external and internal lead time. The time that is wasted between this the realisation and fulfillment is considered to be lean waste of lead time.

12. Little’s law appears quite simple: L = λ W , where L=average number of customers in a stable system, λ= average effective arrival rateand w=average time a customer spends in the system

13ans. WIP is basically that is items in the semi-finished condition (intermediary stage between raw material and finished parts).

WIP can be found in :

a.in front / near the machines

b.on the trlleys/pallets

c.in transit

d.in temporary areas of storage

e.in work distribution centres

15ans. Pull system is basically a system where the producst are pulled from the manufacturing unit based only on the customer demand.

The Attributes of a pull syatem are
• System is initiated at the downstream location bythe Consumer
• Relatively Lesser Inventory
• Information built into the System or Work
• More “Visibility”
• More Instantaneous
• More Flow of Material
• Used where Processing times can be made shortEssentially a “Non-Stock” System . Though stocksmaintained ( if at all ) are done to balance the flow ofmaterial.

16.ans. The keys to create an effective pull system is to have :

a.Good forecasting team for identifying the demand.

b.Responsive supply chain and manufacturing facilities.

c.Logistics team at fast pace.

17. kanban is a system of manufacturing where the supply of components and aseembly is regualted and constantly checked through the use of a instruction card. kanban has 3 bin system in which one bin is on the factory floor (the initial demand point), one bin is in the factory store (the inventory control point), and one bin is at the supplier. The bins usually have a removable card containing the product details and other relevant information, the classic kanban card.

18. Lean 20/80 rule is called the pareto rule which states that 20 percent of the problems caused 80% of the total defects.so if we can remove this 20% of problems the defects will come down by a huge margin. It is discovered by pareto and hence named after him. The pareto graph is a quality tool that can be used for this purpose.

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