Lean Concepts

Question 1

What is a constraint?

Answer 1

anything that limits an organization from moving towards its goal - physical or nonphysical

Question 2

What does constraint identification help with?

Answer 2

assessing overall capability of achieving a performance goal

Question 3

What is the theory of constraints?

Answer 3

the act of identifying the weakest link in a system

Question 4

What are the 3 benefits of using the theory of constraints process?

Answer 4

1) very comprehensive
2) causes people to evaluate the entire process
3) is continuous; loops to the beginning if the process constraint changes

Question 5

What are the five steps of the theory of constraints?

Answer 5

1) identify
2) exploit
3) subordinate
4) elevate
5) repeat

Question 6

What is done in the identify step?

Answer 6

find what is limiting the effectiveness of the system (weakest link or bottleneck)

1) observe process and look for piled up work
2) look for the biggest causes of stress
3) look for steps where work is delayed due to waiting
4) develop flowchart or process map
5) perform value stream mapping and analysis

Question 7

What is done in the exploit step?

Answer 7

use a tool to improve the rate of the constrained process

Ex. PDCA, kaizen, improve inputs, reorganize the workflow, optimize the product mix

Question 8

What is done in the subordinate step?

Answer 8

adjust the performance rates of other processes in the chain to match that of the constrained process

Question 9

What is done in the elevate step?

Answer 9

if the overall system performance rate needs further improvement, the constraining process may require extensive revision. Consider:
- additional capacity
- Six Sigma project
- long-term focus

Question 10

What is done in the repeat step?

Answer 10

find the next system constraint and repeat

Question 11

What are the 3 fundamental questions to ask in the theory of constraints?

Answer 11

1) What to change?
2) What to change to?
3) How to cause the change?

Question 12

What are the 3 measure for evaluation of a system?

Answer 12

1) throughput
2) inventory
3) operational expenses

Question 13

What is a value chain?

Answer 13

a value chain assesses the features, activities, products, or services that add value to both the internal and external customers

Question 14

How is value expressed?

Answer 14

how the specific product or service meets the customer’s needs, at a specific price, at a specific time

Question 15

What are the primary purposes of value chains? (3)

Answer 15

• help management think strategically about the relationship among activities performed inside and outside of the organization
• products and services go on to different organizations that provide additional value before they are sold to customers
• other organizations take those products and services and create finished products for their customers

Question 16

What is flow?

Answer 16

the uninterrupted movement of a product or service through a system to the customer

Question 17

What is the goal of flow?

Answer 17

to achieve continuous motion in which production happens one item as a time without waiting time between processing steps

Question 18

What is perfection in LSS?

Answer 18

providing customers with a product/service that the customer wants in a better way than its competition (safety/health, quality, delivery, cost)

Question 19

Working toward perfection is an ongoing ___________ and _______________ effort.

Answer 19

learning
improving

Question 20

What is hansei?

Answer 20

acknowledging mistakes and pledging to improve