CLL Lean Principles & Value Stream Mapping 2 — Questions and Answers
Question 1: In a Value Stream Map, what does a 'push' arrow indicate?
- Material is pulled based on customer demand
- Material is moved based on a schedule or forecast regardless of downstream need (Correct answer)
- Inventory is eliminated between processes
- A kanban signal has been triggered
Correct answer: Material is moved based on a schedule or forecast regardless of downstream need
A push arrow indicates material is moved forward based on a schedule or forecast, not on actual downstream demand.
Question 2: Which Lean principle focuses on creating smooth, uninterrupted workflow through all process steps?
- Value
- Value Stream
- Flow (Correct answer)
- Pull
Correct answer: Flow
The 'Flow' principle aims to make value-creating steps occur in a smooth, continuous sequence without interruption.
Question 3: What is the primary purpose of the 'Process Box' in a Value Stream Map?
- To represent a single department or supervisor
- To depict a step where material is transformed or information is processed (Correct answer)
- To show inventory accumulation points
- To indicate a quality inspection checkpoint
Correct answer: To depict a step where material is transformed or information is processed
A process box represents any step — manufacturing, assembly, or information processing — where transformation of material or data occurs.
Question 4: A company's current state VSM shows 40 hours of process time but 14 days of lead time. What does this gap primarily represent?
- Equipment downtime
- Transportation distance
- Non-value-added waiting and inventory time (Correct answer)
- Quality rework loops
Correct answer: Non-value-added waiting and inventory time
The large gap between process time and total lead time represents waste in the form of inventory buffers and waiting between steps.
Question 5: Which symbol is used in a VSM to represent the final customer or the starting supplier?
- A triangle with an 'I'
- A factory icon (Correct answer)
- A bold rectangle
- A circle with a lightning bolt
Correct answer: A factory icon
External entities like customers and suppliers are represented by factory-style icons at the top corners of a VSM.
Question 6: What does 'takt time' represent in Lean?
- The actual cycle time of the slowest machine
- The rate at which customers demand one unit of product (Correct answer)
- The time required to set up a machine between runs
- The total processing time across all value-stream steps
Correct answer: The rate at which customers demand one unit of product
Takt time is calculated as available production time divided by customer demand rate, setting the heartbeat of production.
Question 7: In VSM, what is a 'kaizen burst' used to indicate?
- A documented standard work procedure
- An area targeted for immediate improvement in the future state (Correct answer)
- A pull system signal point
- A high-quality certified process step
Correct answer: An area targeted for immediate improvement in the future state
A kaizen burst (starburst symbol) on a VSM flags a specific area where a rapid improvement event is planned for the future state.
CLL Lean Principles & Value Stream Mapping 2
In a Value Stream Map, what does a 'push' arrow indicate?