4.1 Common Lean Tools

Question 1

What is the key goal of all the Lean tools?

Answer 1

To see problems

Question 2

What is the Theory of Constraints?

Answer 2

The theory that in any value stream, one process at a time will constrain the flow of value. Making that process more capable will increase the throughput of the system. Processes that cannot be improved must be prioritized so that they allow as much throughput as possible.

Question 3

What is the goal of a Kanban system

Answer 3

Allows simple scheduling of complicated assembly processes while limiting WIP inventory

Question 4

Does Olympic Steel use Push or Pull production systems?

Answer 4

Both. Most of our customer orders are pull systems. Our raw material orders are usually push systems.

Question 5

What is EOQ?

Answer 5

Economic Order Quantity. The smallest possible batch quantity without spending too much on setup.

Question 6

What is Takt time?

Answer 6

The drumbeat of the customer. Time available divided by quantity required. It tells how fast parts must be produced to match customer demand.

Question 7

Why is one piece flow desirable?

Answer 7

Shortens lead times and reduces in process inventory to react more quickly to customer demand.

Question 8

What is the difference between internal and external processes in SMED?

Answer 8

Internal setup processes require the machine to be down. External setup process can be completed while the machine is running.

Question 9

What are the three components of OEE?

Answer 9

Availability, Productivity, and Quality

Question 10

How are visual management systems and poke yokes related?

Answer 10

Poke yokes are error proofing systems. Often visual management is used to prevent errors or detect them early before they become a problem.