Lean Manufacturing - Wastes Quiz

Overproduction refers to the practice of producing more goods or services than is needed before the demand arises. This can lead to excess inventory, wastage of resources, and increased costs. It is considered a waste in lean manufacturing as it goes against the principle of producing only what is necessary when it is necessary. By producing more than is needed before it is needed, a company may incur unnecessary expenses and tie up valuable resources that could have been utilized more efficiently.

Lead time refers to the total time it takes for a process or task to be completed, from start to finish. It includes both the processing time, which is the time required to complete the actual work or task, and the retention time, which is the time the completed work or task is held or stored before it is used or delivered. Therefore, the correct answer is the sum of the processing time and the retention time.

This answer accurately describes the concept of waiting in a work setting. It refers to any time spent waiting for tools, supplies, parts, or any other necessary items that are required to perform work tasks. This waiting time can occur during the workday and can result in a loss of productivity if it is not managed efficiently.

The term "Value Added Work" refers to any type of work that contributes to enhancing the value of a product. This can include various activities such as welding, painting, cutting, nailing, and more. These tasks are considered valuable because they directly contribute to improving the quality or functionality of the product, making it more desirable or useful to customers. By focusing on value-added work, businesses can prioritize and optimize the activities that directly impact the final product, leading to increased customer satisfaction and potentially higher profits.

This answer suggests that there is a lack of alignment or understanding between different individuals or groups within the company or with suppliers. This could mean that they have different perspectives, goals, or priorities, leading to a disconnect in their ideas and opportunities. This lack of synchronization can hinder effective collaboration and hinder the company's ability to capitalize on potential opportunities.

This answer refers to the concept of motion waste in a manufacturing or assembly process. It suggests that any unnecessary movement or action involved in picking up or stacking parts is considered wasteful. Additionally, it mentions wasted walking, indicating that unnecessary walking or movement between workstations or areas is also a form of motion waste. The overall explanation highlights the importance of minimizing unnecessary motion in order to improve efficiency and productivity in a manufacturing or assembly process.

The term "conveyance" refers to the act of transporting materials, parts, or finished goods between different locations such as storage areas or various processes. In this context, "wasted effort" implies that the transportation is inefficient or unnecessary, resulting in a loss of time, resources, and productivity. This could be due to poor planning, improper organization, or inefficient systems. The correct answer accurately defines conveyance as the unnecessary or inefficient transportation of goods, highlighting the wasteful aspect of this activity.

The correct answer is "Repair or rework, redo." This answer is appropriate because it accurately reflects the meaning of the word "correction." When something is corrected, it means that it is fixed or improved in some way. Repair, rework, and redo all convey the idea of fixing or improving something that was previously incorrect or flawed. Therefore, this answer is a suitable explanation for the given correct answer.

Over processing refers to the act of performing unnecessary or excessive work that does not add value to the final product or service. It involves spending additional time, effort, or resources on tasks that are not required or appreciated by the customer. This can result in wasted time, increased costs, and reduced efficiency. By doing more work than is necessary, organizations may fail to focus on value-added activities and waste resources on non-essential tasks.

Having an excess inventory of raw materials, work in progress (WIP), or finished goods (FG) can be detrimental for a company. It can tie up valuable capital, increase storage costs, and lead to obsolescence or spoilage. Excess inventory can also indicate poor demand forecasting or inefficient production processes. Therefore, it is important for a company to manage its inventory levels effectively to avoid these issues and maintain a healthy cash flow.