Exam (elaborations)
INTRODUCTION TO LEAN MANUFACTURING EXAM QUESTIONS AND ANSWERS
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INTRODUCTION TO LEAN MANUFACTURING EXAM QUESTIONS AND ANSWERS...
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Objective of lean manufacturing - ANSWER A lean approach tomanufacturing is to maximize the value of the product while minimizing waste.
Manufacturers use lean principles to maximize profit, minimize production
costs and eliminate waste in its various forms.
Lean manufacturing - ANSWER a systematic method for waste minimization
within a manufacturing system without sacrificing productivity
Lean thinking principles - ANSWER 1. Specify Value
2. Map the Value Stream
3. Establish Flow
4. Implement Pull
5. Work to Perfection
Specify value - ANSWER Define value from the customer perspective and
express value in terms of a specific product
Map the value stream - ANSWER Map all of the steps...value-added & non-
value added...that bring a product of service to the customer
Establish flow - ANSWER The continuous movement of products, services
and information from end to end through the process
Implement pull - ANSWER Nothing is done by the upstream process until the
downstream customer signals the need
Work to perfection - ANSWER The complete elimination of waste so all
activities create value for the customer by continuous improvement. Use all
principles again, and again
, 5S - ANSWER the core system of Lean made up of five pillars to make
production more efficient and cost effective
1. Sort
2. Set in Order (Straighten)
3. Shine
4. Standardize
5. Sustain
Sort - ANSWER Clearly distinguish needed items from unneeded and
eliminate the latter
Set in Order (Straighten) - ANSWER Keep needed items in the correct place
to allow for easy and immediate retrieval
Shine - ANSWER Keep the workplace neat and clean
Standardize - ANSWER The method by which "Sort," "Straighten" and
"Shine" are made habitual
Sustain - ANSWER Maintain established procedures
The Six Big Losses for Equipment - ANSWER a tool to understand the most
universal forms of waste within manufacturing operations; these losses will
determine the overall equipment effectiveness (OEE)
1. Unplanned Stops (Breakdowns)
2. Planned Stops (Setup & Adjustments)
3. Small Stops
4. Slow Cycles
5. Startup Rejects
6. Production Rejects
OEE - ANSWER overall equipment effectiveness; grouped into three general
areas: loss of availability, performance, or quality.
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