CPM Lean Manufacturing & Waste Reduction Flashcards

What does Overall Equipment Effectiveness (OEE) measure in a lean plant?

Answer: Combined impact of availability, performance, and quality losses

OEE = Availability × Performance × Quality, providing a single metric that captures all major equipment loss categories.

In lean manufacturing, a 'supermarket' refers to:

Answer: A controlled inventory location that replenishes downstream processes via pull signals

A lean supermarket is a strategically located inventory buffer that is replenished by upstream processes only when downstream processes withdraw items.

Which of the following best describes 'heijunka' in a lean production system?

Answer: Production leveling that smooths volume and mix over time

Heijunka levels production by distributing orders evenly over a shift or day to reduce variability and prevent overburden (muri).

A plant manager wants to identify non-value-added activities in a process. Which lean waste category covers unnecessary movement of workers within a workstation?

Answer: Motion

Motion waste refers to unnecessary physical movement by operators (bending, reaching, walking) within their work area, distinct from transportation of materials.

When implementing a pull system, what is the function of a kanban card?

Answer: Authorize the production or movement of a specific quantity of material

A kanban card is a visual signal that authorizes upstream processes to produce or supply a defined quantity only when downstream consumption creates a need.

The 'seven flows' concept in lean manufacturing includes the flow of raw materials, WIP, finished goods, operators, machines, information, and:

Answer: Energy

Energy is the seventh flow in lean manufacturing, and optimizing all seven flows is essential to building a truly waste-free value stream.