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
What is 'first pass yield' (FPY) and why is it important in lean manufacturing?
Answer: The percentage of units that complete a process without rework or rejection, indicating process quality
FPY measures the percentage of units that pass through a process correctly the first time, directly reflecting process quality and waste from defects.
In a value stream map, a 'push arrow' between two processes indicates:
Answer: Material being pushed to the next process based on a schedule regardless of need
Push arrows on a VSM represent material being moved to the next operation based on a schedule or upstream production output, not actual downstream demand.
Which of the following is an example of 'overprocessing' waste in lean manufacturing?
Answer: Applying a paint coat that exceeds customer quality requirements
Overprocessing involves performing more work or using higher-quality materials than required by the customer, adding cost without adding perceived value.
A production supervisor notices some workers are idle while others are overburdened. Which lean concept addresses this condition?
Answer: Mura balancing
Mura (unevenness) balancing through production leveling and line balancing distributes work evenly to eliminate both idle time and overburden across operators.
What is the lean concept of 'visual management' primarily designed to achieve?
Answer: Make the status of operations, problems, and performance instantly visible to everyone
Visual management uses boards, signs, floor markings, and indicators so that anyone can immediately understand the current state of operations without asking.
In lean manufacturing, what is the relationship between lead time and work-in-progress (WIP) inventory?
Answer: Lead time is directly proportional to WIP — more WIP means longer lead time
Little's Law states that lead time equals WIP divided by throughput rate, so reducing WIP directly reduces lead time in a stable system.
Which lean metric would best indicate whether a production line is achieving its planned output rate relative to takt time?
Answer: Line efficiency or production attainment rate
Line efficiency (or production attainment) measures actual output against scheduled output at takt time, showing whether the line is keeping pace with customer demand.