Lean Principles and Philosophy

Question 1

What characteristics belong to lean?

Answer 1

• • Lean management supports the concept of continuous improvement.
• • Continuous improvement focuses on processes and effectiveness.
• • It includes methods, ways of thinking and tools to optimize processes.

Question 2

What is TOS?

Answer 2

Framework and tools to engage all employees in moving the organization towards lean

Question 3

Lead time- also known as “throughput time”

Answer 3

Refers to the time period from placement of an order until the finished product is handed over to the client. This includes all process times, as well as all waiting times (warehouse, inventories ).

Question 4

What are the 7 “rights” in Just-in-time?

Answer 4

right information
right product
right quality
right time
right amount
right place, and
reasonable costs

Question 5

Kaizan means…

Answer 5

Kaizen is a Japanese philosophy of life and work. Its goal is to strive for continuous improvement, also known as the Continuous Improvement Process (CIP).
This triggers small improvements that are always growing and being pursued, but never stopped.

Question 6

Jidoka means…

Answer 6

“intelligent automation”, stopping a process whenever an anomaly occurs.
That way mistakes are not passed on to the next process!
Hence problems can be solved right where they occur and quality is produced.
The principles of Jidoka can be applied, beyond systems and machines, to any process, including manual ones: resolution of customer complaints, identification of material defects, etc

Question 7

What are the 9 lean principles?

Answer 7

Take the long view, go and see, imagine you are the customer, only empowered people produce powerful performance, share openly/borrow proudly, choose the process focus, learn from mistakes, respect partners, keep it simple.

Question 8

Quality

Answer 8

Degree up to which a set of inherent (i.e., intrinsic) characteristics meets requirements.

Question 9

Q-Alarm

Answer 9

Possibility for the worker to get fast and reliable support to rework all defects within the takt.

• -Support for rework needed
• • Supporter finishes the work while the worker moves to the next vehicle
• • The worker needs help

Question 10

Q-Stop

Answer 10

If the problem can’t be solved by the foreman or supporter within the standardized work cycle, the conveyer will stop.
–Problem can’t be solved in the work station

Question 11

What is a fixed position stop?

Answer 11

Here the production conveyor stops at a fixed position that coincides with the end of the work station and the end of a standardized work cycle.

Question 12

Poka Yoke means “error avoidance”, what are three principles that can be utilized?

Answer 12

Mistake proofing

1. Contact principle
2. Fixed-value principle
3. Step-by-step principle

Question 13

How many losses do we consider in a business system?

Answer 13

3

Question 14

What is the goal of a lean organization?

Answer 14

1. Elimination of waste- Shortest processing times, Increased added value
2. Reduction of variability- High availability of machinery and equipment, Standards are put into practice and optimized, High maturity level of products, High process capability
3. Increased flexibility- Flexibility in terms of layout and materials handling technology, Flexibility in terms of machinery and systems, Flexibility in the organization

Question 15

8 types of waste

Answer 15

TIMWOOD+U

Transport, Inventory, Motion, Waiting, Over-processing, Overproduction, Defects + Unutilized people

Question 16

Which type of waste is the worst?

Answer 16

Overproduction is the worst type of waste, as it leads to further waste (in the case of overproduction, too much of everything is manufactured, and all other types of waste also increase as a result).

Question 17

Variability leads to …

Answer 17

Dissatisfied customers or higher costs. Ex material, information

Question 18

Inflexibility leads to …

Answer 18

Inflexibility is expressed in the inability to meet the customer’s requirements (whether it’s a service or a product).
You have a loss of efficiency due to differences between customer demand and the supply of resources.
Underutilization resources or overload and dissatisfied customers or higher costs.

Question 19

PDCA stands for?

Answer 19

Plan– Identify need for action. Plan/design task.
Do– Implement solution
Check– Evaluation of results
Act– Act and go for standardization and sustainability
and/or adjust your plan and try again

Question 20

What statements are true about PDCA?

Answer 20

The PDCA cycle helps to improve a process.

The PDCA cycle is repeated again and again.

The PDCA cycle can also be thought of as Plan - Sprint - Review - Retro.. used in an agile working environment.

Question 21

Value stream

Answer 21

1. A value stream consists of all the activities/ business processes that are necessary to fill an order.
2. Consequently it starts at the customer and ends
   at the customer. It can involve production, product development, customer service, a service rendered, etc.
3. Analysis of the entire value stream enables optimization of the overall system

Question 22

Why do we need to look at the value stream?

Answer 22

To analyze the actual state, to make wastes transparent

Question 23

TOS as our Production System: Leadership and Employees

Answer 23

combine leadership with deep process understanding

Question 24

TOS as our Production System: Standardize Processes

Answer 24

Create the basis for creative improvement with standardized work

Question 25

TOS as our Production System: Stability and Quality

Answer 25

Create simple, robust processes, technology and products

Question 26

TOS as our Production System: Flow and Value Stream

Answer 26

Create value without delay

Question 27

TOS as our Production System: Continuous Improvement

Answer 27

Strive gradually for perfection

Question 28

Project sponsor

Answer 28

Initiates the projects and makes decisions

Question 29

Project leader

Answer 29

Owns the project content and is in control of the project. The project leader is in control of the project. She/he manages the project team, even if the project team is not a team in the organizational context.

Question 30

Experts from the line function

Answer 30

Know the area; plan and implement the operative work on site

Question 31

Consultants

Answer 31

Act in different roles while working with the line function

Question 32

The results of Jidoka are:

Answer 32

1. Quality right from the start and in every process starting with design and extending right up to the customer.
   - - quality stop principle
   - - andon
   - - poka yoke
2. Manual and machine work are separated to increase working productivity.

Question 33

Poka Yoke Avoidance

Answer 33

Avoidance means no transfer of an error.

It’s also called “Soft” Poka Yoke, because the error can still occur.

Question 34

Poka Yoke Prevention

Answer 34

Prevention means an error cannot occur.

It’s also called “Hard” Poka Yoke, because the error can not occur.

Question 35

Poka Yoke “Contact Principle”

Answer 35

Identifying parts through typical characteristics.

Question 36

Poka Yoke “ Fixed Value Principle”

Answer 36

Identifying deviations from fixed values

Question 37

Poka Yoke “Step-by-step Principle”

Answer 37

Identifying deviations from standard processes.

Question 38

Every business consists of 3 steps..

Answer 38

Input, System, Output

Losses in these 3 areas have an impact on performance and output

Question 39

Typical improvement direction

Answer 39

1. To start with, the process is very variable and above the target value.
2. Standardization reduces the process variability and steers the process more strongly in the desired direction.
3. Kaizen measures deliver further process improvements. Variability is minimized and the targeted average cycle time is attained.

Question 40

Value Stream Mapping

Answer 40

Value stream mapping makes it possible to record the actual status of a process along the added-value chain and depict it with standardized symbols. It is the basis of value stream-oriented implementation activities and it generates in-depth process understanding.

Question 41

Value Stream Design

Answer 41

In value stream design visions and target images are developed on the basis of value stream mapping and then implemented.

Question 42

Thinking in processes” / reflecting a value stream can help if …

Answer 42

1. Process issues need to be fully understood before implementing effective measures.
2. Quality of deliverables needs to be ensured under variable conditions.
3. Root causes for problems are unclear among stakeholders.

Question 43

What are the two building blocks that the Daimler TOS is made up of?

Answer 43

1. Lean management philosophy: This is made up of 6 principles. “Gives you the necessary training and support to lead and act leanly.”
2. TOS methods: These can be divided into 5 categories and have different tools. “Use the right tools at the right time and in the right place.”