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 technician notices that a machine frequently breaks down unexpectedly. Which lean-aligned maintenance strategy should be implemented to reduce unplanned downtime?
Answer: Total Productive Maintenance (TPM)
TPM involves all employees in proactive equipment care, using planned maintenance, autonomous maintenance, and focused improvement to eliminate breakdowns.
What is 'standard work' in lean manufacturing?
Answer: A documented, precise description of the safest and most efficient way to perform a task
Standard work documents the best-known method for completing a task at a defined takt time, forming the baseline for continuous improvement.
Which of the following best describes 'mura' in the context of lean manufacturing?
Answer: Unevenness or variation in production flow
Mura refers to unevenness or variability in workflow, workload, or scheduling that creates peaks and valleys disrupting smooth production flow.
An operator repeatedly adjusts a machine that drifts out of specification. Which lean tool would best prevent this problem from recurring?
Answer: Poka-yoke
Poka-yoke (error-proofing) devices or mechanisms prevent errors from occurring or make them immediately obvious before they become defects.
In lean, what does a 'push' production system do that conflicts with lean principles?
Answer: It produces based on forecasts and schedules regardless of downstream readiness
Push systems produce based on forecasts and schedules, often creating excess WIP inventory and overproduction when downstream capacity is unavailable.
Which lean concept emphasizes going to the actual workplace to observe and understand processes firsthand?
Answer: Gemba walk
Gemba, meaning 'the real place,' is the practice of managers and engineers going to the shop floor to observe work, identify waste, and engage with workers.
A lean team wants to reduce changeover time on a stamping press from 4 hours to under 30 minutes. Which methodology should they apply?
Answer: Single-Minute Exchange of Die (SMED)
SMED is a systematic approach to reducing setup and changeover time by converting internal setup steps to external steps and streamlining remaining internal steps.