CLL Lean Principles & Value Stream Mapping 3 — Questions and Answers
Question 1: Which type of waste in the Lean 8 wastes category describes producing more than what the customer currently needs?
- Waiting
- Overproduction (Correct answer)
- Motion
- Defects
Correct answer: Overproduction
Overproduction — making more, earlier, or faster than required — is often called the worst waste because it generates and hides other wastes.
Question 2: When mapping a future state VSM, what is the first question a lean leader should answer according to Lean fundamentals?
- Where should supermarkets be located?
- What is takt time? (Correct answer)
- How many kaizen events are needed?
- What is the current inventory level?
Correct answer: What is takt time?
Establishing takt time is the first step in designing a future state because it synchronizes production pace with customer demand.
Question 3: A VSM timeline shows 'C/T = 45s' below a process box. What does C/T stand for?
- Customer Time
- Cycle Time (Correct answer)
- Change-over Time
- Capacity Takt
Correct answer: Cycle Time
C/T in VSM data boxes denotes Cycle Time — the actual time to complete one unit at that process step.
Question 4: What distinguishes a 'value-added' activity from a 'necessary non-value-added' activity in Lean?
- Value-added activities cost more money
- Value-added activities directly transform the product in a way the customer pays for; necessary NVA activities are required by the business but add no customer value (Correct answer)
- Necessary NVA activities can be eliminated immediately
- Value-added activities always require skilled labor
Correct answer: Value-added activities directly transform the product in a way the customer pays for; necessary NVA activities are required by the business but add no customer value
Value-added steps physically change the product in ways customers value and pay for; necessary NVA steps (like legal compliance) are required but create no direct value.
Question 5: In a Lean value stream, a 'supermarket' represents:
- A centralized warehouse for all raw materials
- A controlled inventory buffer where downstream processes pull what they need (Correct answer)
- A push-based scheduling point
- A finished goods stockroom
Correct answer: A controlled inventory buffer where downstream processes pull what they need
A supermarket is a precisely sized, managed inventory point from which a downstream process pulls only what it needs, when it needs it.
Question 6: Which Lean concept states that improvement should be pursued endlessly, even after perfection seems achieved?
- Just-in-Time
- Jidoka
- Perfection (Pursue Perfection) (Correct answer)
- Heijunka
Correct answer: Perfection (Pursue Perfection)
The fifth Lean principle — Pursue Perfection — holds that as waste is removed, more waste becomes visible, creating a continuous improvement cycle.
Question 7: What does the 'VA%' metric measure in VSM analysis?
- The percentage of processes using automation
- The proportion of total lead time that is value-adding process time (Correct answer)
- The percentage of employees trained in Lean
- The volume of production that meets quality standards
Correct answer: The proportion of total lead time that is value-adding process time
VA% (Value-Added Ratio) = total value-added time ÷ total lead time, and is typically very low (often under 5%), revealing improvement opportunity.
CLL Lean Principles & Value Stream Mapping 3
Which type of waste in the Lean 8 wastes category describes producing more than what the customer currently needs?