Manufacturing and Production Lean Manufacturing 2 — Questions and Answers
Question 1: The '5S' methodology stands for Sort, Set in Order, Shine, Standardize, and:
- Survey
- Supply
- Sustain (Correct answer)
- Simplify
Correct answer: Sustain
The fifth S is Sustain, which ensures the other four steps are maintained and become part of daily routine.
Question 2: What is 'poka-yoke' designed to do?
- Speed up assembly
- Prevent errors or make them immediately obvious (Correct answer)
- Reduce labor costs
- Increase batch sizes
Correct answer: Prevent errors or make them immediately obvious
Poka-yoke is an error-proofing technique that prevents defects by making it impossible or difficult to make mistakes.
Question 3: In lean, 'overproduction' is considered the worst waste because:
- It uses the most energy
- It generates all other wastes by producing more than needed (Correct answer)
- It requires the most labor
- It damages equipment
Correct answer: It generates all other wastes by producing more than needed
Overproduction leads to excess inventory, transportation, storage costs, and masks other process problems.
Question 4: Which lean concept involves producing one unit at a time through a sequence of operations?
- Batch processing
- One-piece flow (Correct answer)
- Push production
- Mass production
Correct answer: One-piece flow
One-piece flow moves single units through production steps sequentially, reducing WIP and lead times.
Question 5: A 'pull system' in lean manufacturing means:
- Workers pull materials from a central warehouse
- Production is triggered by actual customer demand (Correct answer)
- Machines pull raw materials automatically
- Supervisors pull workers to critical areas
Correct answer: Production is triggered by actual customer demand
In a pull system, downstream demand signals upstream processes to produce, preventing overproduction.
Question 6: What is 'heijunka' in lean manufacturing?
- Machine calibration
- Production leveling to smooth out demand variation (Correct answer)
- Supplier qualification
- Quality inspection
Correct answer: Production leveling to smooth out demand variation
Heijunka is the practice of leveling production volume and mix over time to reduce variability and waste.
Manufacturing and Production Lean Manufacturing 2
The '5S' methodology stands for Sort, Set in Order, Shine, Standardize, and: