Lean production
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Question
What is lean production?
Answer
Cutting waste and maximising efficiency — produce more value using fewer resources. If it doesn't add value, eliminate it.
💡 Hint
Cut waste, max efficiency
Question
Three benefits of lean production?
Answer
Lower costs, higher quality, faster production, more motivated workers, better use of space.
💡 Hint
Costs + quality + speed
Question
Five lean production tools?
Answer
JIT, Kaizen, cellular manufacturing, TQM, cradle to cradle.
💡 Hint
JIT-K-Cell-TQM-C2C
Question
Lean applies beyond manufacturing to ___
Answer
Services, hospitals (reduce patient waiting), retail (manage inventory), tech — any industry.
💡 Hint
All industries
Question
Lean links to: JIT, Kaizen, cellular manufacturing, ___
Answer
TQM and cradle to cradle — all part of the lean philosophy.
💡 Hint
TQM + C2C
Question
Six types of waste in lean thinking?
Answer
Overproduction, waiting time, excess inventory, defects, unnecessary movement, over-processing.
💡 Hint
O-W-I-D-M-P
Question
All lean tools share the same goal: ___
Answer
Eliminate waste, improve quality, add more value for the customer.
💡 Hint
Eliminate waste + quality + value
Question
Three challenges of lean production?
Answer
Requires culture change, vulnerable to supply disruptions, high training costs, takes time, pressure on suppliers.
💡 Hint
Culture + supply risk + training
Question
Lean is vulnerable to supply disruptions because ___
Answer
Low stock means no buffer — if a supplier is late, production stops immediately.
💡 Hint
No buffer stock
Question
Lean = less waste, more ___
Answer
Value — every step should add value for the customer.
💡 Hint
Value
Read the notes
Full study notes for Lean production
Topic 5.3 hub
Lean production and quality management (HL only)
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