Lean Manufacturing Assessed Learning Exam

1- Quiz - Introduction: Lean Thinking for Manufacturing and Automation

Question 1 *

Lean manufacturing thinking can be applied to automation by:

Using the control loop as a starting point for lean automation design
Hardware simplification
Streamlined wiring
Using standard IEC 61131-3 control programming software
All of the above
Question 2 *

The video cites Bob Yenkner’s “Glossary of Lean Manufacturing” tutorial article in Control Engineering -- which of the following are among lean manufacturing terms cited?

Set-up or changeover - Total time required to change from the last good piece with old tooling to the first good piece with new tooling.
Kaizen - Continuous, incremental improvement of an activity to create more value with less waste.
Kanban - A signaling device or process that gives instruction for production or conveyance of items in a pull system. This can be a signal, a card, or even a designated open space on the floor.
Poka-yoke - A mistake-proofing device, method, or procedure to prevent a defect from occurring during the process.
All of the above
Question 3 *

Eight types of waste, as described, are:

Underproduction, waiting, stopping, process inefficiencies, inventory, un-automated motions, defective products, and unused creativity.
Overproduction, Gemba, moving, process inefficiencies, breakthrough Kaizen, unnecessary motions, defective products, and unused creativity.
Overproduction, waiting, moving, process inefficiencies, inventory, unnecessary motions, defective products, and unused creativity.
All of the above
None of the above
Question 4 *

In lean manufacturing, the process of going to the place where a problem exists to see, observe, and deeply understand the situation through personal observation, data gathering, and analysis is called:

Standard work
Set-up or change over

2- Quiz - Start with the Control Loop: Essence of Lean Automation

Question 1 *

As described, a simple control loop is...?

Sense, decide, actuate (and repeat)
Process disturbance, process reaction, process remediation
Setpoint compensation, control effort, process improvement
None of the above
It depends on how automation is applied
Question 2 *

A diagram showed how control loops can operate in a distributed fashion, with logic in the center, feeding the operator interface, actuators, and sensors through input and output I/O connections. Which correctly matches equipment in that example?

Operator interface: motor starters and pneumatic valves Actuators: proximity switches, flowmeters; and Sensors: push buttons, pilot lights, and potentiometers
Operator interface: push buttons, pilot lights, and potentiometers Actuators: motor starters and pneumatic valves; and Sensors: proximity switches, flowmeters
Operator interface: proximity switches, flowmeters Actuators: motor starters and pneumatic valves; and Sensors: push buttons, pilot lights, and potentiometers
None of the above
There was no such diagram
Question 3 *

In the feedback control loop diagram shown:

Disturbances cause oscillations beyond the sensor’s ability to compensate
The controller computes the error between the setpoint and the process variable, then applies a control effort to the process to reduce the error over time.
Bode loop analysis, Nyquist zone, nonlinear control, and fuzzy logic are all can be applied to exceed the setpoint when needed.
A and C
None of the above

3- Quiz - Lean Automation: Integrated Hardware

Question 1 *

Industrial control can occur in desktop computers, industrial PCs, loop controllers, programmable logic controllers, programmable automation controllers, operator interfaces, human-machine interface, embedded controllers, network or I/O-based controller, board-level controllers, and systems on a chip. According to this video, select the true statement:

Moving input/output modules closer to control always represents the greatest savings in lean automation.
Building in triple redundancy represents the greatest savings in lean automation.
Lean automation always combines operator interface, sensors, and actuators in one device.
None of the above
Question 2 *

Lean thinking in automation hardware: To streamline network communications, the back of operator interface example shown had: 

Long I/O terminal strips for field wiring
Network ports
Four hardwired connections
A wireless transmitter

4- Quiz - Lean Automation: Simpler Wiring

Question 1 *

Lean thinking applied to automation, in part, reduces wiring. Rich Harwell told Doug Bell that generally takes:

55 seconds to wire one push button
1-2 minutes to wire one push button
4-10 minutes to wire one push button
10-12 minutes to wire one push button
None of the above
Question 2 *

In the before and after views of a control cabinet, the “after” view, by using networking and device integration eliminated: 

PLC and I/O cards
Operator interface
Sensors and actuators
Motors starters and push buttons
All of the above
Question 3 *

Did you read the fine print? The partially visible sign on the side of the “after” control cabinet says lean automation control cabinet design can produce space savings of:

Up to 5%
Up to 15%
Up to 25%
Up to 35%
None of the above

5- Quiz - Lean Automation: IEC 61131 Standard Programming

Question 1 *

True or false: IEC 61131-3 standard control programming languages provide structure and reduce waste in software programming. Rules for each allow greater usability of programming and easier reuse and modification later. Benefits include software based on Program Organization Units (POUs) to provide consistent structure.

Question 2 *

Which isn’t a correct statement about IEC 61131-3 languages discussed:

Relay ladder logic (RLL or LL) – derived from use of electrical relays, prior to programmable logic controllers. It is good for simple, discrete logic, but cumbersome for more complex control.
Function block diagram (FBL) – graphical language based around encapsulating logic in a re-usable block of code
Sequential function chart (SFC) – defines logic in terms of moving from one state to another in a machine or process
Instruction list (IL) – similar to assembly level machine code
Structured text (ST) – more of a C-like language, often appealing to those with computer programming experience
Trick question: they’re all correct

6- Quiz - Lean Automation: CoDeSys demo

Question 1 *

Some software can add complexity by limiting interchangeability, making it more challenging to work across controllers. CoDeSys, an open software for industrial automation, is an IEC 61131-3 programming system and a runtime system. It can allow:

A programmer to more comfortably move among various control elements, easily adapting from one vendor “target” device to another
Decreased training involved by avoiding the need to use multiple vendors’ programming software platforms
Automated programming of a first draft of code in the best language or languages for that application
All of the above
A and B
Question 2 *

According to Rich Harwell in the video, CoDeSys has been adopted by: 

More than 200 manufacturers
Fewer than 50 manufacturers
100 automation software vendors
No one knows
Question 3 *

In the demo, when selecting the Program Organization Units (POUs), the screen shows a sixth language among selections (beyond than the five previously discussed). The sixth is:

CFC, Continuous Function Chart, a high-level graphical language similar to function block diagram, adding ability for parallel computing of multi-thread algorithms
CDS, a special CoDeSys programming language that translates all known code into any other language
OSI, open software importation, with ability to import any software code
Question 4 *

CoDeSys development environment, as noted in the demo:

Allows mixing of languages
Permits libraries and reuse of blocks of code
Has tools specific to each language
All of the above
B and C
Question 5 *

After adding resources and selecting target, the last part of the software demo:

Chooses the optimal control programming language
Writes the simple software program developed in the laptop to the hardware shown on the bench
Dismisses everyone for lunch
None of the above

7- Quiz - Key points: Lean Thinking for Manufacturing and Automation

Question 1 *

This video series covered:

Lean manufacturing terms
Using the control loop as a starting point for lean automation design for discrete and process automation
How lean manufacturing thinking can be applied to automation hardware simplification and streamlined wiring
How lean automation applies to software, such as standard IEC 61131-3 software, and use of CoDeSys as a more-open method of applying lean thinking to control programming
All of the above
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