Lean Basics Interview Questions

Checkout Vskills Interview questions with answers in Lean Basics to prepare for your next job role. The questions are submitted by professionals to help you to prepare for the Interview.

Q.1 What is value in Lean?

The Value in lean is everything the customer is willing to pay for and also refers to the level of fulfilling a customer’s requirement by the product or service.

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Q.2 What is affinity diagram?

An Affinity Diagram in six sigma is a tool which gather ideas, opinions and issues which are organized into homogeneous groupings or subgroups based on their natural relationships for developing solutions. The Affinity process is often used to group ideas generated by Brainstorming.

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Q.3 What is spaghetti diagram?

A spaghetti diagram visually representation using a continuous flow line tracing the path of an item or activity through a process. It enables process teams to identify redundancies in the work flow and opportunities to expedite process flow.

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Q.4 What is Pull in Lean?

Pull refers to the movement in production as per requirements or pull by the customer. A pull system is a lean manufacturing strategy used to reduce waste in the production process as, components used in the manufacturing process are only replaced once they have been consumed so companies only make enough products to meet customer demand.

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Q.5 Which waste elimination technique focus on organizing the workplace?

5S technique focus on organizing the workplace.

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Q.6 Which TQM technique is used under lean manufacturing?

The 5S TQM technique is used under lean manufacturing.

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Q.7 What does the Japanese word seiri refers to?

Seiri refers to Sorting out.

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Q.8 Who creates demand in process line under pull system?

Next operation creates demand in process line under pull system.

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Q.9 Where is muri technique primarily applied?

The muri technique is applied for new product design.

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Q.10 What does Gemba walk results in?

Gemba walk results in identification of place of value addition under Lean.

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Q.11 What is Lean thinking, and what are its core principles?

Lean thinking is a philosophy that aims to maximize value while minimizing waste. Core principles include customer focus, continuous improvement, and waste reduction.

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Q.12 Which 5S phase results in usage of color codes?

The second phase or Seiton or Orderliness results in usage of color codes.

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Q.13 What is the primary goal of Lean manufacturing?

The primary goal is to eliminate waste (non-value-added activities) to improve efficiency, quality, and customer satisfaction.

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Q.14 What do you understand by SMED?

SMED or Single-Minute Exchange of Die is a system for dramatically reducing the time it takes to complete equipment changeovers. It focuses to convert as many changeover steps as possible to “external” (performed while the equipment is running), and to simplify and streamline the remaining steps.

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Q.15 What are the eight types of waste in Lean, often referred to as "Muda"?

The eight types of waste are overproduction, waiting, unnecessary transportation, overprocessing, excess inventory, motion, defects, and underutilized skills.

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Q.16 What do you understand by Kanban?

Kanban is a visual method for managing workflow at the individual, team, and even organizational level. Kanban visualizes both the process (the workflow) and the actual work passing through that process. The goal of Kanban is to identify potential bottlenecks in your process and fix them.

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Q.17 Can you explain the concept of "value stream mapping" in Lean?

Value stream mapping is a visual tool used to analyze and optimize the steps and activities required to deliver value to the customer, helping identify and eliminate waste.

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Q.18 What is a Kanban Card?

In Kanban, work items are represented by cards and can be imagined as sticky notes on the whiteboard. Each card, or sticky note, represents one work item.

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Q.19 What is the difference between Lean and Six Sigma methodologies?

Lean focuses on waste reduction and process efficiency, while Six Sigma aims to reduce defects and variations in processes. Both can be used together (Lean Six Sigma) for comprehensive improvements.

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Q.20 What is a value stream?

Value Streams are the processes taken by an organization to create solutions that deliver a constant flow of value to a customer.

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Q.21 What is "5S" in Lean, and what are its five components?

5S is a workplace organization methodology. Its five components are Sort, Set in order, Shine, Standardize, and Sustain.

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Q.22 What is poka yoke?

Poka-yoke is a Japanese term that means mistake-proofing or inadvertent error prevention. A poka-yoke is any mechanism in a process that helps an equipment operator avoid mistakes and defects by preventing, correcting, or drawing attention to human errors as they occur.

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Q.23 Explain the concept of "Kaizen" in Lean.

Kaizen is the practice of continuous improvement involving small, incremental changes made by employees at all levels to enhance processes and operations.

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Q.24 What is Fishbone diagram?

Fishbone or Ishikawa diagram is a diagram which shows the potential causes of a problem by categorizing them to identify its root causes.

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Q.25 What is "Just-In-Time" (JIT) production in Lean?

JIT is a production approach that aims to produce and deliver products only when they are needed, minimizing inventory and associated costs.

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Q.26 What is FMEA?

FMEA or Failure Modes and Effect Analysis, is a risk assessment tool which evaluates the severity, occurrence, and detection of risks to prioritize the most urgent or impactful ones.

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Q.27 How does Lean approach the reduction of defects and errors?

Lean addresses defects by identifying root causes, standardizing processes, and continually improving to prevent defects from occurring.

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Q.28 How do you define the problem statement?

The problem statement for a lean project should be clear and defined in metrics for easy understanding by all the stakeholders and also explain to them the consequences if not resolved.

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Q.29 What role does "takt time" play in Lean production scheduling?

Takt time is the rate at which a product must be produced to meet customer demand. It helps synchronize production with customer requirements.

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Q.30 What do you understand by a feasibility study?

The feasibility study is used to identify the success rate of a proposed idea for a business problem. The study helps identify new opportunities and their likely impact or benefit. It helps decide on which proposed idea will be the most beneficial.

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Q.31 What is "Kanban" in Lean, and how does it facilitate production control?

Kanban is a visual signaling system that helps manage inventory levels, production, and material flow, ensuring items are produced only when needed.

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Q.32 What is Mistake-Proofing?

Mistake-Proofing is about adding controls to prevent defects, reduce their severity, and detect them if they can occur.

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Q.33 How does Lean promote employee involvement and empowerment?

Lean encourages employees to identify problems, suggest improvements, and actively participate in decision-making, creating a culture of engagement.

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Q.34 Which technique with Heijunka box is used for pull production?

Kanban is used for pull production with Heijunka box

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Q.35 What is the "Andon" system, and how does it relate to Lean manufacturing?

The Andon system is a visual signaling method that alerts workers to problems in real-time, enabling quick responses and problem-solving.

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Q.36 What does the one-piece-flow refers to?

The one-piece-flow refers to one piece only moving to the next operation

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Q.37 Explain the concept of "Poka-Yoke" and its role in Lean quality control.

Poka-Yoke refers to mistake-proofing techniques that prevent errors and defects from occurring during the production process.

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Q.38 What is a method for maintaining an orderly flow of material?

Kanban is a method for maintaining an orderly flow of material

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Q.39 What is the "Gemba" in Lean, and why is it important?

Gemba means the actual place where work happens. It's crucial for Lean practitioners to go to the Gemba to understand processes, identify waste, and make improvements.

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Q.40 What is TPM?

TPM is a technique which focuses on proactive and progressive maintenance of equipments by utilizing the knowledge of operators, equipment vendors, engineering and support persons to optimize machine performance

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Q.41 How does Lean address uneven production and workload balancing?

Lean aims to balance workloads through techniques like Heijunka (production smoothing) to avoid overburdening employees and equipment.

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Q.42 What triggers production demand when using kanban?

Removal of product by the downstream customer, triggers production demand when using kanban

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Q.43 What is "Jidoka" in Lean, and how does it relate to quality control?

Jidoka refers to automation with human intelligence. It enables machines to stop automatically when defects are detected, preventing further production of defective items.

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Q.44 What should be the approach for products with low demand?

JIT approach product to be produced in the quantity needed

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Q.45 How does Lean manufacturing improve lead times and delivery to customers?

Lean reduces waste and streamlines processes, allowing for shorter lead times and faster delivery of products or services to customers.

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Q.46 What is Takt Time?

Takt time refers to the rate at which you must finish a product in order to meet client demand. If you receive a new product order every four hours, for example, your team must complete a product in four hours or fewer to meet demand. Takt is an important measure of output against demand.

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Q.47 Explain the concept of "single-piece flow" in Lean production.

Single-piece flow, or one-piece flow, means producing items one at a time rather than in batches, reducing inventory and lead times.

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Q.48 What are the seven waste products in Lean?

Muda refers to the wastes and the seven waste products in Lean are overproduction, inventory, motion, defects, over-processing, waiting, and transport.

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Q.49 What is the role of "value-added" and "non-value-added" activities in Lean analysis?

Value-added activities directly contribute to the product or service, while non-value-added activities do not and are considered waste. Lean aims to minimize non-value-added activities.

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Q.50 Which 5S phase involves going through all the contents of a workspace to determine which are needed and which can be removed?

The first or Seiri or sort phase of 5S involves going through all the contents of a workspace to determine which are needed and which can be removed.

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Q.51 How does Lean address the issue of excess inventory in production?

Lean reduces excess inventory by implementing JIT principles, producing only what is needed, and using Kanban systems to control materials.

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Q.52 What is "Total Productive Maintenance" (TPM) in Lean, and why is it important?

TPM is a system for maintaining equipment to prevent breakdowns and defects, maximizing machine efficiency and reliability in Lean production.

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Q.53 How does Lean encourage a culture of continuous improvement?

Lean fosters continuous improvement by encouraging employees to identify problems, suggest solutions, and make incremental changes to processes.

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Q.54 Explain the concept of "standard work" and its role in Lean manufacturing.

Standard work involves documenting and consistently following the best-known practices to ensure process stability and repeatability.

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Q.55 What are "KPIs" (Key Performance Indicators) in the context of Lean management?

KPIs are metrics used to measure performance and progress in Lean initiatives, such as cycle time, defect rate, and inventory turnover.

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Q.56 How does Lean address the reduction of lead time in manufacturing processes?

Lean reduces lead time by eliminating waste, streamlining processes, and improving the flow of materials and information.

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Q.57 What is the role of "5 Whys" in root cause analysis in Lean problem-solving?

The "5 Whys" technique involves asking "why" repeatedly to identify the root cause of a problem and address it effectively in Lean.

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Q.58 How does Lean differentiate between "value stream" and "process"?

A value stream includes all activities from customer order to delivery, while a process is a specific set of activities within the value stream. Lean focuses on optimizing both.

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Q.59 What is the concept of "continuous flow" production in Lean, and why is it beneficial?

Continuous flow production means producing items without interruption, reducing work-in-progress and achieving smoother processes in Lean.

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Q.60 How does Lean address the challenge of uneven customer demand?

Lean addresses uneven demand through production smoothing, leveling production schedules, and flexible workforce planning.

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Q.61 What role does "visual management" play in Lean production and process improvement?

Visual management uses visual cues like charts, graphs, and displays to make information and performance visible, aiding communication and process control in Lean.

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Q.62 How does Lean address the reduction of setup times (SMED - Single Minute Exchange of Die)?

Lean reduces setup times by analyzing and streamlining changeover processes, using standardized work instructions and efficient tooling.

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Q.63 Explain the concept of "pull system" and how it differs from a "push system" in Lean.

A pull system produces items based on customer demand, while a push system produces items regardless of demand, leading to overproduction in Lean.

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Q.64 What is the role of "Karakuri Kaizen" in Lean manufacturing?

Karakuri Kaizen involves using simple, low-cost mechanical devices to assist in manual handling and improve ergonomics in Lean production.

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Q.65 How does Lean address the reduction of transportation waste in supply chains?

Lean reduces transportation waste by optimizing routes, consolidating shipments, and minimizing unnecessary movements of materials or products.

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Q.66 What is "One-Piece Flow," and why is it preferred in Lean production?

One-Piece Flow refers to the practice of producing a single item at a time. It reduces inventory, minimizes waste, and enhances quality control in Lean.

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Q.67 What is "Heijunka" in Lean, and how does it help in production scheduling?

Heijunka is production smoothing, allowing for a consistent production rate to meet customer demand, reducing the impact of fluctuations in demand in Lean.

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Q.68 How does Lean address the reduction of motion waste in manufacturing processes?

Lean reduces motion waste by optimizing workstations, eliminating unnecessary movements, and ensuring tools and materials are readily accessible.

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Q.69 What is the role of "work cells" in Lean production, and how do they differ from traditional assembly lines?

Work cells are self-contained production units where a team performs a complete process. They offer flexibility and faster response to changes compared to traditional assembly lines in Lean.

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Q.70 Explain the concept of "point-of-use" storage in Lean, and why is it important?

Point-of-use storage involves storing materials or tools near the location where they are needed, reducing time wasted searching for items and improving efficiency in Lean.

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Q.71 How does Lean address the reduction of excess processing and overproduction?

Lean reduces excess processing and overproduction by eliminating unnecessary steps, producing only what is needed, and optimizing processes.

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Q.72 What is the role of "visual control boards" in Lean manufacturing?

Visual control boards display key performance metrics, production targets, and other information to provide real-time visibility and facilitate decision-making in Lean.

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Q.73 How does Lean apply the "Plan-Do-Check-Act" (PDCA) cycle for continuous improvement?

PDCA is used in Lean as a structured approach to problem-solving and improvement: plan a change, do it, check the results, and act on the findings to implement improvements.

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Q.74 What is the significance of "Total Quality Management" (TQM) in Lean?

TQM emphasizes quality at every stage of production, aligning with Lean's goal of waste reduction and continuous improvement in quality.

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Q.75 How does Lean address the reduction of excess inventory in the supply chain?

Lean reduces excess inventory by implementing JIT principles, minimizing buffer stock, and collaborating closely with suppliers.

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Q.76 What is the "5S + Safety" approach in Lean, and why is safety a critical component?

5S + Safety includes the standard 5S components along with a focus on safety. Safety is crucial to protect employees and maintain a productive work environment in Lean.

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Q.77 How does Lean manage the balance between the conflicting goals of minimizing inventory and ensuring product availability?

Lean manages this balance through demand forecasting, flexible production systems, and efficient supply chain management.

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Q.78 Explain the concept of "Hoshin Kanri" (Policy Deployment) in Lean management.

Hoshin Kanri is a strategic planning process that aligns organizational goals, strategies, and actions to achieve continuous improvement in Lean.

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Q.79 What is the role of "standardized work" in Lean, and how does it relate to process stability and improvement?

Standardized work documents the best-known way to perform a task, providing a stable foundation for improvement and consistency in Lean.

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Q.80 How does Lean address the reduction of waiting times and delays in processes?

Lean reduces waiting times and delays by optimizing workflows, synchronizing processes, and minimizing idle time for employees or equipment.

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Q.81 Explain the concept of "value stream analysis" in Lean, and why is it a critical step in process improvement?

Value stream analysis identifies value-added and non-value-added activities, helping prioritize areas for improvement and waste reduction in Lean.

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Q.82 How does Lean incorporate feedback loops and continuous learning into its principles?

Lean encourages feedback from employees and customers, fostering a culture of continuous learning, adaptation, and improvement.

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Q.83 What are "Quick Changeover" (SMED) techniques, and why are they important in Lean production?

Quick Changeover techniques reduce setup times, allowing for quicker production changeovers and flexibility in meeting customer demand in Lean.

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Q.84 Explain the concept of "batch size reduction" in Lean manufacturing.

Batch size reduction involves producing smaller quantities at a time, reducing inventory and enabling more frequent production changes in Lean.

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Q.85 What is the role of "value-added analysis" in Lean process improvement?

Value-added analysis helps differentiate activities that directly contribute to customer value from those that do not, aiding in waste elimination and Lean improvement efforts.

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Q.86 How does Lean address the reduction of defects and variations in processes?

Lean reduces defects and variations by implementing standardized work procedures, error-proofing methods, and continuous improvement practices.

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Q.87 Explain the concept of "empowerment" in Lean, and how does it relate to employee involvement?

Empowerment in Lean means giving employees the authority and responsibility to make decisions and take actions to improve processes and outcomes.

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Q.88 How does Lean manage the reduction of excess motion and handling in manufacturing?

Lean reduces excess motion by organizing workspaces, optimizing layouts, and eliminating unnecessary movements that do not add value.

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Q.89 What is the role of "single-minute exchange of die" (SMED) in Lean manufacturing?

SMED techniques reduce the time it takes to change from one production task to another, improving flexibility and responsiveness in Lean.

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Q.90 How does Lean address the challenge of underutilized skills and talents in the workforce?

Lean encourages skill development and cross-training to utilize the full potential of employees, matching skills with tasks effectively.

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Q.91 Explain the concept of "flow production" and its importance in Lean manufacturing.

Flow production focuses on achieving a smooth, uninterrupted flow of work, minimizing bottlenecks and inefficiencies in Lean.

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Q.92 What is the "Andon cord" in Lean manufacturing, and how does it function?

The Andon cord is a visual and audible signal used by employees to stop production when a problem is detected, promoting immediate problem-solving in Lean.

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Q.93 How does Lean address the reduction of excess inventory in the distribution and supply chain processes?

Lean employs strategies like vendor-managed inventory (VMI), consignment inventory, and demand-driven replenishment to minimize excess inventory in the supply chain.

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Q.94 What is the role of "visual displays" in Lean, and how do they enhance communication and transparency?

Visual displays provide real-time information on performance, goals, and issues, promoting transparency and alignment with Lean principles.

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Q.95 Explain the concept of "jidoka" (autonomation) in Lean, and why is it considered a quality control tool?

Jidoka involves automating processes while giving machines the ability to detect defects and stop production, ensuring quality and reducing waste in Lean.

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Q.96 How does Lean address the reduction of excess transportation and handling waste in processes?

Lean reduces transportation and handling waste by optimizing material flow, minimizing unnecessary movements, and streamlining logistics.

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Q.97 What is the "Plan-Do-Check-Act" (PDCA) cycle, and how does it apply to Lean continuous improvement?

PDCA is a four-step method (Plan, Do, Check, Act) used in Lean for iterative problem-solving and continuous improvement of processes.

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Q.98 How does Lean differentiate between "value-creating time" and "non-value-creating time" in processes?

Value-creating time is the time spent directly adding value to a product or service, while non-value-creating time includes delays, waiting, and other forms of waste in Lean.

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Q.99 What is "A3 problem solving," and how does it help in Lean improvement projects?

A3 problem solving is a structured approach for solving problems and making decisions, often using an A3-sized sheet of paper for documentation and communication in Lean.

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Q.100 How does Lean address the reduction of excess defects and rework in production?

Lean reduces defects and rework by identifying root causes, implementing process improvements, and promoting quality at every stage.

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Q.101 What is "value stream improvement" in Lean, and why is it significant for process optimization?

Value stream improvement focuses on analyzing and optimizing the entire value stream, aiming to eliminate waste and improve efficiency in Lean.

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Q.102 How does Lean apply "error-proofing" or "poka-yoke" techniques to prevent mistakes and defects?

Lean uses error-proofing techniques such as checklists, guides, and physical devices to prevent errors and defects from occurring in processes.

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Q.103 Explain the concept of "continuous flow manufacturing" in Lean, and its role in reducing waste.

Continuous flow manufacturing involves producing items one at a time, achieving a smooth, continuous flow of work, and minimizing waste in Lean.

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Q.104 What is "value stream synchronization" in Lean, and why is it essential for minimizing waste?

Value stream synchronization aligns processes and activities to customer demand, reducing waste and achieving efficient, synchronized production in Lean.

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Q.105 How does Lean manage the reduction of excess inventory in the retail and distribution sectors?

Lean retail and distribution reduce excess inventory through demand-driven replenishment, efficient stocking practices, and close collaboration with suppliers.

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Q.106 What role does "5S" play in Lean workplace organization, and how does it contribute to waste reduction?

5S establishes an organized and efficient workplace by eliminating clutter, optimizing layouts, and reducing waste associated with disorganization in Lean.

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Q.107 Explain the concept of "pull production" and its benefits in Lean manufacturing.

Pull production involves producing items based on customer demand, reducing overproduction, excess inventory, and associated waste in Lean.

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Q.108 How does Lean address the reduction of excess processing steps and complexity in manufacturing?

Lean simplifies processes by eliminating unnecessary steps, focusing on value-added activities, and minimizing complexity to reduce waste.

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Q.109 What is "Total Productive Maintenance" (TPM) in Lean, and how does it improve equipment reliability?

TPM involves proactive equipment maintenance to prevent breakdowns, improve machine reliability, and enhance overall efficiency in Lean.

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Q.110 How does Lean foster a culture of continuous improvement and employee engagement?

Lean encourages a culture of continuous improvement through employee involvement, empowerment, and the pursuit of waste reduction and process optimization.

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