Learning About Lean

What is Lean?

Lean is a philosophy that focuses on creating value for the customer while minimizing waste. It’s about efficiency, flow, and constant improvement.

The 5 Lean principles are:

1. Identify Value

2. Map the Value Stream

3. Create Flow

4. Establish Pull

5. Pursue Perfection.

Organizations that practice Lean reduce waste, improve quality, cut costs, and create happier employees and customers.

Value Stream Mapping

What is VSM?

Value Stream Mapping (VSM) is a Lean tool that visually represents all the steps in a process — both value-adding and non-value-adding. It helps you identify bottlenecks, delays, unnecessary motion, and waste. By seeing the entire flow of materials and information from start to finish, you can spot where improvements will have the biggest impact.
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5S Organization

What is 5S?

5S is a Lean method that creates a clean, organized, and efficient environment by applying five steps: Sort: Eliminate what’s unnecessary Set in Order: Arrange tools and items for ease of use Shine: Clean and inspect your space Standardize: Create routines and standards Sustain: Maintain the system over time
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The 7 Wastes

What are the 7 Wastes?

Overproduction, Waiting, Transport, Over-processing, Inventory, Motion, and Defects. These are waste types Lean helps eliminate.
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5 Whys

What is the 5 Whys?

Ask “Why?” repeatedly to discover the root cause of a problem, not just the surface issue.
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Lean Knowledge Check

Ready to test your Lean knowledge? This short quiz covers the core practices you’ve just learned and practiced.

Quiz: 5S Organization

Quiz – Value Stream Mapping

Quiz – The 7 Wastes

Quiz – 5 Whys

Answer Key – 5S Quiz

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.

Answer Key – Value Stream Mapping Quiz

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?
✅ Correct Answer: Customer names
📌 VSM focuses on process elements like steps, inventory, wait times, and handoffs. Individual customer data is not typically included unless specifically relevant to process variation.

 

The 7 Wastes Answer Key

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.

Answer Key – 5 Whys Quiz

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.