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Lean Implementation and Continuous Improvement Flashcards

7 cards from real LMC practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

Read the first 7 Lean Implementation and Continuous Improvement flashcards as text

  1. A lean team discovers that 40% of defects originate in a single process step. Which tool is BEST suited to prioritize root cause investigation?

    Answer: Pareto chart

    A Pareto chart ranks defect causes by frequency, revealing the vital few issues (80/20 rule) that drive the majority of problems.

  2. During a kaizen event, the team wants to reduce motion waste in an assembly cell. Which technique directly maps worker movement paths?

    Answer: Spaghetti diagram

    A spaghetti diagram traces the actual physical movement of workers or materials, making motion waste visible.

  3. Standard work is best described as:

    Answer: The documented current best method that forms the baseline for improvement

    Standard work captures the current best-known method and creates a stable baseline from which continuous improvement can be measured.

  4. A plant manager wants to level production output across shifts to match average customer demand. This scheduling approach is called:

    Answer: Heijunka (production leveling)

    Heijunka levels the volume and mix of production over time to reduce overburden, unevenness, and inventory fluctuations.

  5. Which lean metric measures the percentage of time a process actually adds value to the product versus total lead time?

    Answer: Process cycle efficiency (PCE)

    Process cycle efficiency (PCE) is calculated as value-added time divided by total lead time, typically less than 5% in traditional manufacturing.

  6. A continuous improvement team identifies that inventory between two workstations frequently exceeds the target quantity. The FIRST lean action should be:

    Answer: Investigate the upstream process for overproduction or speed imbalance

    Excess inventory between stations signals an upstream pacing or flow problem; addressing the root cause prevents recurrence rather than treating the symptom.

  7. In a lean pull system, a kanban signal is triggered when:

    Answer: A downstream process consumes a container of parts

    Kanban is a demand-driven signal: consumption by a downstream process authorizes replenishment, preventing overproduction.