Lean Operations

Question 1

Muda

Answer 1

do not add value to the operation or the customer.

Question 2

Mura

Answer 2

means ‘lack of consistency’ or unevenness that results in periodic overloading of staff or equipment

Question 3

Muri

Answer 3

the idea that unnecessary or unreasonable requirements put on a process will result in poor outcomes

Question 4

gemba walk ( looking for waste)

Answer 4

if you really want to understand something, you go to where it actually takes place

Question 5

Visual stream mapping

Answer 5

It visually maps a product or services ‘production’ path from start to finish

Question 6

5S

Answer 6

sort, Straighten, shine, standardize, sustain

Question 7

Lean

Answer 7

achieve a flow of materials, information or customers that delivers exactly what customers want, in exact quantities, exactly when needed, exactly where required and the lowest cost possible.

Question 8

Lean is a philosophy of how to run operations

Answer 8

involvement of staff, drive for continuous improvement, elimination for waste

Question 9

Lean is a method of planning a controlling operation

Answer 9

achieve synchronized flow and reduce waste

Question 10

Lean is a set of tools that improve performance

Answer 10

collection of improvement tools and techniques that are the means for cutting out waste

Question 11

Improvement ( kaizen )

Answer 11

meet demand instantaneously with perfect quality and no waste

Question 12

Waste

Answer 12

an activity does not add value

Question 13

Waste from irregular flow

Answer 13

waiting time, transport, process inefficiencies, inventory, and wasted motion

Question 14

Waste from inexact supply

Answer 14

Over- or under production, early/late delivery, inventory

Question 15

Waste of inflexible response

Answer 15

Large batches, Delays between activities, more variation on activity mix than in customer demand

Question 16

Visual Management

Answer 16

utilizes a noticeboard, computer screen or signals which convey what is happening

• act as communication mechanism
• encourage commitment to agreed goals
• facilitate co-operation between team members

Question 17

Small scale process technology

Answer 17

can produce various products and services simultaneously

Question 18

Pull control

Answer 18

let downstream stage pull items through the system

Question 19

Levelled scheduling

Answer 19

keeping the mix and volume of flow between stages at an even rate over time

Question 20

Levelling delivery schedules

Answer 20

delivering smaller quantities more often can reduce inventory

Question 21

Total Productive Maintenance ( TPM )

Answer 21

aims to eliminate the variability in operations processes caused by the effect of breakdowns

Question 22

Theory of Constraints

Answer 22

to increase profit by increasing the throughput of a process or operation. Focusing on constraints in the process

Question 23

Materials requirements planning (MRP)

Answer 23

process that helps companies make volume and timing calculations