25 Lean Methods

Question 1

Kanban P.557

Answer 1

A system that signals the need to replenish stock or materials or to produce more of an item.

Question 2

5S P.559

Answer 2

• Sort
• Set (arrange)
• Shine (clean)
• Standardize
• Sustain

Question 3

Poka-Yoke P. 560

Answer 3

Mistake-proof a process by building safeguards into the system that avoid or immediately find errors.

Question 4

Continuous Flow Manufacturing (CFM) P.563

Answer 4

Method in which items are produced and moved from one processing step to the next at a time.

Question 5

Single-minute exchange of die (SMED) P.564

Answer 5

• Identify and classify internal (machine down) and external activities (preparation/ followup)
• Make a video of the changeover process
• Separate internal and external activities
• Convert internal to external activities
• Apply engineering changes to convert any remaining internal activities to external activities as appropriate.
• Minimize external activity time

Question 6

Heijunka (Production Leveling) P. 565

Answer 6

• Volume Leveling

- Product Leveling

Question 7

Kaizen Event or Kaizen Blitz P.568

Answer 7

Small, intensive event or project over a relatively short duration, such as a week.

• The responsibility for implementation of changes as a result of the kaizen activity lies mostly within the team, and the risk of failure is small.
• Projects are time bounded and results must be demonstrated quickly.
• Projects are clearly defined.
• Improvement opportunities are readily identifiable, such as excess waste.

Question 8

Kaizen P.569

Answer 8

An approach to process and enterprise management that recognizes the importance of each employee’s creative ability and interest in continuous improvement.

Question 9

Theory of constraints (TOC) P.570

Answer 9

A problem-solving methodology that focuses on the weakest link in a chain of processes.

1. Identify
2. Exploit (improve constraint)
3. Subordinate (adjust rate to match constraint)
4. Elevate
5. Repeat

Question 10

Overall equipment effectiveness (OEE) P.573

Answer 10

OEE = Availability x Performance x Quality

Availability = Actual operation time / Planned production tim

Performance = (Total pieces / Actual operating time) / Ideal run time

Quality = Number of good pcs/ Total number of pcs