Lean Implementation and Continuous Improvement Flashcards
7 cards from real LMC 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 Implementation and Continuous Improvement flashcards as text
In lean thinking, 'mura' refers to:
Answer: Unevenness or variation in workload and production
Mura (unevenness) causes alternating periods of overload and idle time; addressing it through leveling reduces both muri (overburden) and muda (waste).
An operator notices a machine producing out-of-specification parts and pulls an andon cord. The PRIMARY lean purpose of the andon system is to:
Answer: Immediately signal a problem so it can be addressed before more defects are made
Andon is a visual and audible alert system that stops the line and draws immediate attention to quality or process issues, embodying jidoka principles.
Which continuous improvement approach involves all employees submitting small, incremental improvement ideas on an ongoing daily basis?
Answer: Daily kaizen (teian system)
Daily kaizen or teian (suggestion system) harnesses the collective knowledge of the entire workforce through a continuous stream of small improvements.
A value stream map shows a large inventory triangle between two process steps with 12 days of supply. What does this primarily indicate?
Answer: A significant flow disruption or imbalance exists between those steps
Large inventory accumulations in a VSM reveal disconnected processes, batch scheduling, or capacity imbalances that impede flow.
The 'Plan-Do-Check-Act' (PDCA) cycle is fundamental to lean because it:
Answer: Creates a structured, scientific approach to testing and learning from changes
PDCA embeds hypothesis-driven experimentation into continuous improvement, ensuring changes are tested at small scale before full deployment.
A lean coach observes that a team's 5S audit scores improved significantly but defect rates remained unchanged. The MOST likely explanation is:
Answer: The team focused on appearance rather than the quality-related disciplines of 5S
Superficial 5S compliance (tidiness) without addressing the standardize and sustain phases rarely impacts quality unless the root of the defect is disorder-related.
Which of the following is a key characteristic of a lean 'pull' production system compared to a 'push' system?
Answer: Work-in-process inventory is minimized by triggering production only when downstream signals exist
Pull systems limit WIP by authorizing production only when a downstream signal (e.g., kanban) indicates actual need, reducing inventory and lead time.