Department Case Studies
Comprehensive and Detailed Stories of Lean implementation that have been divided up by the specific department they were incorporated into, highlighting the unique processes and outcomes achieved within each area.
Comprehensive and Detailed Stories of Lean implementation that have been divided up by the specific department they were incorporated into, highlighting the unique processes and outcomes achieved within each area.
Q1: What is the purpose of the 5 Whys method?
✅ Correct Answer: To identify the root cause of a problem
📌 Asking “Why?” repeatedly helps move past symptoms and surface-level causes toward something actionable that can be improved.
Q2: When should you stop asking “Why?” during the 5 Whys process?
✅ Correct Answer: When you identify a cause that is within your control and can be addressed
📌 The goal is not to reach an arbitrary number or assign blame — it’s to reach the point where you can intervene meaningfully.
Q1: Which of these is a type of waste in Lean?
✅ Correct Answer: Overproduction
📌 Overproduction happens when more is made than needed or before it’s needed — leading to excess inventory, defects, or delay.Q2: “Motion” waste refers to:
✅ Correct Answer: Unnecessary movement of people during a process
📌 This includes walking, reaching, or shifting frequently between tools or workstations — often overlooked but cumulative in cost.
Q1: What is the primary purpose of Value Stream Mapping?
Correct Answer: To visualize a process and identify waste
VSM maps out every step in a process to show how materials and information flow — highlighting delays, inefficiencies, and opportunities to improve.
Q2: Which of the following is least likely to appear on a value stream map?
Q1:
❌ Incorrect Option: “Simplify”
✅ Correct Answer: Sort, Shine, Sustain are all part of 5S — Simplify is not.
Q2:
✅ Correct Answer: “Shine” means clean the workspace and inspect for problems.