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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. The DMAIC improvement cycle stands for Define, Measure, Analyze, Improve, and:

    Answer: Control

    The Control phase in DMAIC ensures that improvements are sustained through monitoring plans, control charts, and updated standard work.

  2. Which waste category in the 8 wastes of lean describes producing more than the next downstream process or customer immediately needs?

    Answer: Overproduction

    Overproduction is often called the 'mother of all wastes' because it creates or hides other wastes like excess inventory, waiting, and transportation.

  3. A team uses error-proofing devices to make defects physically impossible or immediately detectable. The lean term for this approach is:

    Answer: Poka-yoke

    Poka-yoke refers to mistake-proofing mechanisms that prevent errors from occurring or that detect them instantly at the source.

  4. During value stream mapping, a 'push' arrow between two process boxes indicates:

    Answer: Material is pushed forward based on a schedule or batch completion

    A push arrow shows that material is produced and forwarded to the next step regardless of downstream demand, a common source of overproduction.

  5. A lean practitioner wants to reduce changeover time from 3 hours to under 10 minutes. The BEST framework to apply is:

    Answer: Single-Minute Exchange of Die (SMED)

    SMED systematically converts internal setup steps to external ones and streamlines remaining internal steps to dramatically cut changeover time.

  6. Which of the following best describes the concept of 'jidoka' in lean manufacturing?

    Answer: Empowering workers or machines to stop and signal when an abnormality is detected

    Jidoka (autonomation) gives machines and workers the authority to stop production when a defect is found, preventing defects from being passed downstream.

  7. A company measures its lean maturity and finds that improvements frequently regress after kaizen events. The MOST likely root cause is:

    Answer: Failure to update and enforce standard work after improvement

    Without updated standard work and management follow-up to sustain new methods, gains erode as workers revert to old habits.