Lean Quality Management Flashcards

'Andon' in lean manufacturing refers to:

Answer: A visual and/or audible alert system that signals an abnormality or problem in the production process

Andon (Japanese for 'lantern') is a visual management tool — often a light or board — that alerts supervisors and team members to quality or production problems requiring immediate attention.

'Heijunka' in lean production refers to:

Answer: Production leveling — smoothing out the type and volume of production evenly over a fixed period

Heijunka levels production by spreading out the volume and mix of products evenly over time, reducing the peaks and valleys that create waste and strain on the value stream.

The '5 Whys' technique is used to:

Answer: Identify the root cause of a problem by repeatedly asking 'why' until the fundamental cause is found

The 5 Whys method drills down through layers of symptoms to find the root cause of a problem by asking 'why' repeatedly until the true cause is revealed.

A 'gemba walk' involves:

Answer: Managers going to the actual workplace to observe processes, engage employees, and identify waste first-hand

Gemba (Japanese for 'the real place') walks bring leaders to where value is created to observe, ask questions, and understand the true state of processes rather than relying solely on reports.

In lean, 'muda,' 'mura,' and 'muri' represent:

Answer: Waste, unevenness, and overburden — the three sources of inefficiency targeted by lean

Lean targets all three: muda (non-value-added waste), mura (unevenness in flow), and muri (overburden of people and equipment), forming the complete waste elimination framework.

The 8 wastes of lean manufacturing are often remembered by the acronym DOWNTIME, where the 'N' stands for:

Answer: Non-utilized talent

DOWNTIME stands for Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, and Extra-processing — the eight categories of lean waste.