Lean Operations Flashcards

Which lean tool uses a visual card system to signal replenishment and control work-in-progress inventory?

Answer: Kanban

Kanban uses physical or digital cards to authorize production or movement of materials, pulling inventory only when needed.

In lean warehousing, 'heijunka' refers to:

Answer: Leveling production volume and mix over time

Heijunka is the practice of leveling the type and quantity of production over a fixed period to reduce unevenness (mura).

A warehouse notices workers walking long distances to retrieve tools. Which of the 8 wastes does this represent?

Answer: Motion

Unnecessary motion of people—such as excessive walking or reaching—is classified as the motion waste in lean thinking.

What is the primary purpose of a 'gemba walk' in a lean warehouse?

Answer: Observing actual work conditions at the point of activity

A gemba walk involves leaders going to the actual workplace to observe processes, identify waste, and engage with frontline workers.

Which metric measures the ratio of value-added time to total lead time in a process?

Answer: Process Cycle Efficiency (PCE)

Process Cycle Efficiency equals value-added time divided by total lead time, revealing how much time is truly productive.

In lean operations, 'jidoka' (autonomation) means:

Answer: Machines detect abnormalities and stop automatically

Jidoka empowers machines and workers to stop production immediately upon detecting a defect, preventing defects from passing downstream.

A 'milk run' delivery system in lean logistics is best described as:

Answer: A fixed-route, fixed-schedule vehicle collecting from multiple suppliers

A milk run uses a scheduled route to pick up small, frequent deliveries from multiple suppliers, reducing inventory and improving flow.