Lean Principles & Value Stream Mapping Flashcards
7 cards from real CLL 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 Principles & Value Stream Mapping flashcards as text
A manufacturer reduces batch size from 500 units to 50 units between two processes. What Lean outcome does this most directly support?
Answer: Reduced lead time and faster feedback on quality issues
Smaller batch sizes reduce WIP inventory and lead time, and surface quality defects faster since fewer units are produced before a problem is detected.
In the 5 Lean Principles, 'identifying the value stream' means:
Answer: Analyzing all specific actions required to deliver a product or service and classifying each step as value-added or waste
Value stream identification requires mapping every action from raw material to customer and categorizing each step as value-adding, necessary non-value-adding, or pure waste.
What is the term for the type of waste added to Ohno's original 7 wastes by many Lean practitioners, specifically referring to underutilized human creativity and skills?
Answer: Non-utilized talent
Non-utilized talent (or underutilized people) is the 8th waste added beyond Ohno's original seven, recognizing that failing to engage employees' ideas is itself wasteful.
On a VSM, an inventory triangle with 'I' and a number beneath it represents:
Answer: Observed inventory accumulation between process steps at the time of mapping
The triangle with 'I' on a VSM marks where inventory physically exists in the stream and shows the quantity observed during the mapping exercise.
Which lean tool is most directly used alongside VSM to maintain the gains made in a future state implementation?
Answer: Standard Work
Standard Work documents the best-known method to sustain future-state conditions, preventing regression to old habits after improvements are made.
A VSM data box shows C/O = 2 hours for a stamping press. From a Lean perspective, this metric primarily signals an opportunity to apply which tool?
Answer: Single-Minute Exchange of Die (SMED)
A long changeover time (C/O) is directly addressed by SMED, which systematically reduces setup time to enable smaller, more frequent production runs.
When a VSM team observes a process step where operators inspect every unit 100% of the time, this is best classified as which category of waste?
Answer: Overprocessing
100% inspection is a form of overprocessing — applying more effort than necessary — and signals the need to address root causes rather than screen for defects after the fact.