Lean Manufacturing Principles Flashcards
7 cards from real CPT 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 Manufacturing Principles flashcards as text
A manufacturer groups similar machines together in one area of the plant. From a lean perspective, this layout is most likely to cause which type of waste?
Answer: Overproduction and excess inventory
Functional (departmental) layouts often lead to large batch production and work-in-progress inventory building up between departments.
What is the primary goal of implementing cellular manufacturing in a lean environment?
Answer: Reducing lead time by co-locating equipment for product families
Cellular manufacturing arranges equipment and workstations into a U-shaped or linear cell dedicated to a product family, minimizing transport and wait time.
During a kaizen event, a team discovers that operators walk 300 feet to retrieve components. Which waste category does this fall under?
Answer: Motion
Motion waste refers to unnecessary movement of people, such as walking long distances to retrieve parts, tools, or materials.
What does 'heijunka' mean in lean production?
Answer: Production leveling to smooth out volume and mix over time
Heijunka is the practice of leveling the production schedule by quantity and variety to reduce unevenness (mura) and overburden (muri).
Which metric measures the percentage of time a process is available, performing, and producing quality output?
Answer: Overall Equipment Effectiveness (OEE)
OEE combines Availability, Performance, and Quality rates into one metric to identify how effectively manufacturing equipment is being used.
In a lean pull system, production is triggered by:
Answer: Actual downstream customer or process demand
A pull system produces only in response to actual demand signals from downstream processes or customers, reducing overproduction and excess inventory.
What is the purpose of a 'red tag' in a 5S implementation?
Answer: To identify items that are questionable and may not belong in the work area
Red tags are applied during the Sort step of 5S to items whose necessity is uncertain, placing them in a red-tag holding area for evaluation.