Yellow Belt Chapter 4: Lean Concepts

Question 1

The Seven Muda

Answer 1

Lean concepts are based on muda which are things that waste labor, time, and resources causing money.

7 muda/wastes:
overproduction, correction, inventory, motion, conveyance, over-processing, waiting
(COIM-COW)

Question 2

Overproduction (single unit-for a product)

Answer 2

Overproduction-

a product or service that was produced too fast, too much of a product, or @ wrong time.

Question 3

Correction

Answer 3

Correction-
when a defect exists and that causes the defect to be resent to be correctly produced; causes waste in labor and extra cost.

Question 4

Inventory (refers to overproduction of whole product)

Answer 4

Inventory- muda referring to the build up of final products that are made at wrong time, too fast, or too many.

Question 5

Motion

Answer 5

Motion- repetitive and unnecessary actions that cause problems with double-entry

ex: use sphagetti diagrams

Question 6

Conveyance

Answer 6

Conveyance- similar to motion muda but particular to outputs, products, or resources

Question 7

Over-Processing

Answer 7

Over-processing muda-

when more resources (time, labor, money) are put into a product than it is required.

Question 8

Waiting

Answer 8

waiting muda-
caused when there is an excess in time wasted from one process to another.

***caused by non-coordinated processing steps

Question 9

Other Forms of Waste

Answer 9

Talent
Ideas
Capital/Cash

Question 10

Talent

Answer 10

Talent Muda- hiring the wrong person for the job who has more talent in other more advanced areas that are not being used.

Question 11

Ideas

Answer 11

Ideas muda- when thoughts and ideas of people are discounted

Question 12

Capital/Cash

Answer 12

capital/cash muda-

not properly using the capital to create more cash flow

Question 13

The Two Types of Muda

Answer 13

Type I Muda-
* Type I muda are a category of muda that results from the creation of necessary checkpoints and quality measures for a product to protect from product defects.

Type II Muda-
The regular types of muda defined above in (COIM-COW and TIC).

No use to management!

Question 14

5S (Phase 1: Sort)

Answer 14

Sort Phase- you will remove all unnecessary items from process and keep all necessary items in the process.

Question 15

5S (Phase 2: Straighten)

Answer 15

After you sort, you must straighten. Each Value-Adding item is given a home to streamline the process with tape or numbers to designate the items.

Question 16

5S (Phase 3: Shine)

Answer 16

After straightening, you must shine the item.

-Shine process means that you will keep the process clean and neat. Please put all equipment where it belongs from “straighten phase.”

Question 17

5S (Phase 4: Standardize)

Answer 17

Standardize means to create an “understood protocol” for everyone to follow. These steps will be followed accordingly:

• “Sort, Straighten, Shine”

Question 18

5S (Phase 5: Sustain)

Answer 18

Sustain:

If we use 5S, we must sustain it. Everyone must sustain the organizations 5S design.

Question 19

Just-In-Time Manufacturing

Answer 19

JIT shorthand; meaning thst each process is synchronized with another process. These processes are combined together working perfectly.

Also, can refer to meeting customers demands when required to.

Question 20

Lean Concepts that crop up in many improvement methodologies

Answer 20

N/A