Lean Foundations and Principles

Question 1

What is the purpose of Lean?

Answer 1

To reduce waste in the value stream and provide maximum value to our customers; do more with less.

Question 2

What are the Lean methodologies?

Answer 2

1. Just-in-time
2. Poka-Yoke
3. Kanban
4. Value-stream mapping

Question 3

What is a Value Stream?

Answer 3

The series of activities that a organisation performs in order to deliver products and services.

Question 4

What are the main components of a value stream?

Answer 4

1. The flow of materials
2. The transformation of inputs to outputs
3. The flow of information

Question 5

What is 5S?

Answer 5

1.Sort
2. Set in Order
3. Shine
4. Standardise
5. Sustain

Question 6

In the 5S system, what does Sort mean?

Answer 6

Remove unneeded items, clean up the work area.

Question 7

In the 5S system, what does Set in Order mean?

Answer 7

Arrange items for ease of accessibility - a place for everything and everything in its place.

Question 8

In the 5S system, what does Shine mean?

Answer 8

Cleaning the work area and equipment.

Question 9

In the 5S system, what does Standardise mean?

Answer 9

Develop checklists, standards and work instructions to keep the work area clean and orderly.

Question 10

In the 5S system, what does Sustain mean?

Answer 10

Sustain the cleanliness and organisation of the work area by embedding the process.

Question 11

What is Kaikaku?

Answer 11

Breakthrough improvement, or kaizen event.

Question 12

What is Kaizen?

Answer 12

Change for improvement.

Question 13

How long does Kaikaku last?

Answer 13

3 to 5 days.

Question 14

What is a “Pull System”?

Answer 14

A component of Just in Time, where a process produces only when there is pull from the subsequent process.

Question 15

What is Just In Time?

Answer 15

An inventory strategy where the delivery of material or product happens only at the exact time and place it will be used.

Question 16

What is kanban?

Answer 16

A system for improving system control by ensuring timely movement of products and information.

Question 17

What is Poka-Yoke?

Answer 17

A system for built in “mistake-proofing”, or “error-proofing” to prevent errors.

Question 18

What is Standard Work?

Answer 18

A tool that defines the interaction between person and machine with three components;

1. Standard time
2. Standard inventory
3. Standard sequence

Question 19

What does the Standard Work tool do?

Answer 19

Helps train new operators and reduce variation in the process.

Question 20

Lean experts define a process step as value added if?

Answer 20

1. The customer recognises the value
2. It changes the product
3. It is done right the first time

Question 21

What is muda?

Answer 21

Waste

Question 22

What are the types of muda?

Answer 22

1. Overproduction
2. Excess motion
3. Waiting
4. Inventory
5. Excess movement of material
6. Defect correction (rework)
7. Excess processing
8. Lost creativity (underutilisation of resource skills)