Assessment & Evaluation Methods Flashcards

Which tool is used to visually separate causes of a problem into major categories during a lean assessment?

Answer: Fishbone diagram

The fishbone (Ishikawa) diagram organizes root causes into categories like People, Process, Machine, and Environment.

A lean team wants to evaluate whether a process change sustained its gains over 90 days. What is the BEST method?

Answer: Control chart tracking key metrics over time

Control charts reveal whether a process remains in statistical control and sustains improvement gains over time.

What does 'takt time' measure in lean evaluation?

Answer: Rate of customer demand divided by available production time

Takt time = available production time ÷ customer demand rate, setting the pace the process must match.

During a gemba walk, a lean practitioner should primarily focus on:

Answer: Observing actual work conditions and talking to frontline workers

Gemba walks emphasize going to the actual place of work to observe real conditions and engage workers directly.

Which metric best evaluates the efficiency of a lean process by comparing value-added time to total lead time?

Answer: Process cycle efficiency (PCE)

PCE = value-added time ÷ total lead time, directly measuring how much of the total time actually adds value.

When a 5S audit score drops sharply in 'Sustain,' what is the most likely root cause?

Answer: Daily disciplines and accountability checks are lacking

Low Sustain scores indicate insufficient daily routines, visual management, or leadership follow-through to maintain standards.

A pull system is best evaluated by measuring:

Answer: Work-in-process (WIP) inventory levels between stations

WIP inventory between stations directly shows whether downstream demand is controlling upstream production as intended by pull.