Lean Manufacturing Principles Flashcards

In lean manufacturing, what does the term 'Muda' refer to?

Answer: Any activity that consumes resources without adding value

Muda is the Japanese term for waste — any activity that uses resources but does not add value from the customer's perspective.

Which lean tool is used to visually display the current state and future state of a process flow?

Answer: Value Stream Map

Value Stream Mapping (VSM) documents and analyzes the flow of materials and information from supplier to customer, enabling identification of waste.

A production line that manufactures only what is needed, when it is needed, and in the amount needed is practicing which lean concept?

Answer: Just-in-Time (JIT)

Just-in-Time (JIT) is a lean strategy that aligns raw material orders with production schedules to reduce inventory waste.

What is the purpose of a Kanban card in a lean production system?

Answer: To signal when materials or parts need to be replenished

Kanban cards serve as visual signals that trigger the movement, production, or supply of a specific item within a pull system.

Which of the 8 wastes in lean manufacturing refers to producing more than what is currently needed by the next process or customer?

Answer: Overproduction

Overproduction is considered the worst lean waste because it generates other wastes such as excess inventory, transportation, and storage costs.

In lean terminology, what is 'Takt time'?

Answer: The available production time divided by customer demand rate

Takt time synchronizes production pace with customer demand by dividing available production time by the number of units customers require.

Which lean principle focuses on making defects immediately visible and stopping production when abnormalities occur?

Answer: Jidoka

Jidoka, also called 'autonomation,' empowers workers and machines to stop the line when a defect is detected, preventing defective products from passing downstream.