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Tools and Techniques in Lean Flashcards

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  1. What distinguishes a 'pull' system from a 'push' system in Lean production?

    Answer: Pull produces only when downstream demand signals it; push produces based on schedules

    In a pull system, production is triggered by actual downstream consumption, preventing overproduction; a push system produces according to forecasts regardless of real demand.

  2. A Lean team maps a process and identifies a 'queue' icon with 200 units waiting between two workstations. What type of waste does this represent?

    Answer: Inventory

    Work-in-process inventory piling up between workstations is classified as the waste of inventory, one of the eight Lean wastes.

  3. In value stream mapping, what does a 'push arrow' (striped arrow) indicate?

    Answer: Material is being pushed to the next process regardless of demand

    The push arrow in VSM shows that material moves forward based on a schedule or upstream capacity rather than downstream demand.

  4. Which Lean technique involves leveling both production volume and product mix over time?

    Answer: Heijunka

    Heijunka (production leveling) smooths out demand variation by distributing different product types and quantities evenly across a production period.

  5. What is the primary purpose of a 'shadow board' in 5S implementation?

    Answer: Provide an immediately visible storage location and instantly show when a tool is missing

    A shadow board has outlines of each tool so anyone can instantly see what belongs where and whether any tool is out of place or missing.

  6. During a Kaizen event, a team discovers that an operator walks 50 feet to retrieve parts on every cycle. Which Lean tool would best eliminate this motion waste?

    Answer: Workplace reorganization using 5S and cell design

    Redesigning the workstation layout using 5S principles and cellular design places materials and tools within reach, eliminating unnecessary motion.

  7. What does 'Jidoka' mean in Lean manufacturing?

    Answer: Autonomation—equipment automatically stops when a defect is detected

    Jidoka (autonomation) gives machines the ability to detect abnormalities and stop automatically, preventing defects from flowing downstream.