LMC Documentation & Record Management 2 — Questions and Answers
Question 1: In lean management, what is the primary purpose of a Standard Work Combination Sheet?
- To record machine maintenance schedules
- To document the sequence of human, machine, and walking time for a task (Correct answer)
- To track defect rates by operator
- To log daily production targets
Correct answer: To document the sequence of human, machine, and walking time for a task
A Standard Work Combination Sheet documents the interplay of manual time, machine time, and walking time to show how an operator completes a cycle.
Question 2: Which document is used to visually map the flow of materials and information in a lean value stream?
- SIPOC diagram
- Value Stream Map (VSM) (Correct answer)
- RACI matrix
- Control chart
Correct answer: Value Stream Map (VSM)
A Value Stream Map (VSM) depicts both material and information flows from supplier to customer, highlighting waste and improvement opportunities.
Question 3: What does 'document control' mean in the context of a lean quality management system?
- Limiting the number of documents employees can access
- Ensuring documents are approved, distributed, and revised in a controlled manner (Correct answer)
- Archiving all documents after one year
- Converting paper documents to digital format
Correct answer: Ensuring documents are approved, distributed, and revised in a controlled manner
Document control ensures that only current, approved versions are in use and that changes follow a defined review and approval process.
Question 4: A kaizen event team updates a process procedure but forgets to revise the related training record. This is an example of:
- A documentation gap / record inconsistency (Correct answer)
- Normal document lifecycle behavior
- A 5S audit finding only
- An acceptable deviation per lean standards
Correct answer: A documentation gap / record inconsistency
Failing to update linked records when a process changes creates documentation gaps that undermine traceability and training alignment.
Question 5: In ISO 9001-aligned lean systems, what distinguishes a 'document' from a 'record'?
- Documents are digital; records are paper-based
- Documents state intent or requirements; records provide evidence of activities performed (Correct answer)
- Records are created by management; documents by operators
- Documents expire; records do not
Correct answer: Documents state intent or requirements; records provide evidence of activities performed
Documents (procedures, work instructions) describe what should happen, while records (completed checklists, inspection logs) prove what did happen.
Question 6: Which lean principle most directly drives the practice of maintaining minimal but sufficient documentation?
- Respect for people
- Eliminate waste (muda) (Correct answer)
- Flow
- Pull
Correct answer: Eliminate waste (muda)
Excess documentation is a form of waste; lean documentation aims to include only information that adds value to process execution or compliance.
Question 7: What is the recommended approach when a lean team discovers two conflicting versions of the same work instruction in use on the shop floor?
- Allow each shift to use whichever version they prefer
- Immediately identify the current approved version, remove obsolete copies, and investigate how the duplicate arose (Correct answer)
- Archive both versions and create a third consensus version
- Escalate to senior management without touching the documents
Correct answer: Immediately identify the current approved version, remove obsolete copies, and investigate how the duplicate arose
Conflicting versions must be resolved by reinstating the single approved document and using root cause analysis to prevent recurrence.
LMC Documentation & Record Management 2
In lean management, what is the primary purpose of a Standard Work Combination Sheet?