10+ DesignNBuy Interview Questions and Answers

Some common lean tools implemented at the shop floor include 5S, value stream mapping, kanban, and kaizen.

• 5S - Sort, Set in order, Shine, Standardize, Sustain

• Value stream mapping - Identifying value-added and non-value-added activities in the process

• Kanban - Visual signaling system to trigger production or replenishment

• Kaizen - Continuous improvement through small incremental changes

Project management involves planning, organizing, and executing projects using tools and techniques to achieve specific goals.

• Project management tools like Gantt charts, Kanban boards, and project management software help in planning and tracking progress.

• Techniques such as Agile, Waterfall, and Scrum methodologies are used to manage projects efficiently.

• Effective communication, risk management, and stakeholder engagement are key aspects of project management.

• Examples: Using ...read more

Lean techniques focus on eliminating waste and improving efficiency in processes.

• Lean techniques involve identifying and eliminating waste in processes to improve efficiency.

• Uses in real life include implementing just-in-time inventory systems, reducing lead times, and streamlining production processes.

• Lean techniques can also be applied in service industries to improve customer satisfaction and reduce costs.

• Examples include Toyota's production system, Six Sigma methodology, ...read more

Six Sigma and Lean Black Belt methodologies are used in consulting to improve processes and reduce waste.

• Six Sigma focuses on reducing defects and variation in processes

• Lean Black Belt focuses on eliminating waste and improving efficiency

• Combining both methodologies can lead to significant improvements in quality and productivity

• Examples of using Six Sigma and Lean Black Belt in consulting include streamlining supply chain processes, improving customer service operations, and...read more

5-S is a methodology for organizing a workplace for efficiency and effectiveness by identifying and storing items used, maintaining the area and items, and sustaining the new order.

• Sort - Separate needed tools, parts, and instructions from unneeded items.

• Set in order - Arrange items so they are easy to use and label them to show where items belong.

• Shine - Clean the work area and equipment regularly.

• Standardize - Establish schedules and methods for maintaining and monitoring t...read more

Heat treatment process is a method used to alter the physical and sometimes chemical properties of a material through heating and cooling.

• Involves heating the material to a specific temperature

• Holding it at that temperature for a certain amount of time

• Then cooling it at a controlled rate

• Common types include annealing, tempering, quenching, and normalizing

OEE stands for Overall Equipment Effectiveness and productivity refers to the efficiency of a process or system.

• OEE is a metric used to measure the performance of manufacturing equipment.

• It takes into account three factors: availability, performance, and quality.

• Productivity is a measure of how efficiently resources are used to produce goods or services.

• It can be calculated by dividing output by input.

• Improving OEE and productivity can lead to increased profitability and comp...read more

Lean manufacturing is a systematic approach to identifying and eliminating waste in the production process.

• Focuses on continuous improvement and waste reduction

• Involves all employees in the process

• Uses tools such as value stream mapping and 5S

• Examples include Toyota Production System and Kaizen

Cycle time and Takt time are two types of time used in manufacturing processes.

• Cycle time is the time it takes to complete one cycle of a process or operation.

• Takt time is the rate at which a product must be produced in order to meet customer demand.

• Cycle time can be used to identify bottlenecks and inefficiencies in a process.

• Takt time can be used to set production goals and improve efficiency.

• Other types of time used in manufacturing include lead time, processing time, and ...read more

Takt time is the rate at which a product must be produced to meet customer demand.

• Takt time is calculated by dividing available production time by customer demand.

• It helps in determining the pace of production to meet customer demand.

• It is used in Lean manufacturing to eliminate waste and improve efficiency.

• For example, if a company has 480 minutes of production time and customer demand is 240 units, the takt time would be 2 minutes per unit.

• Takt time can be adjusted based on...read more

Gemba walk is a Lean management practice where managers go to the actual workplace to observe processes, identify waste, and engage with employees.

• Gemba walk involves going to the actual workplace where value is created

• The purpose is to observe processes, identify waste, and engage with employees

• It helps in understanding the current state of operations and opportunities for improvement

• Examples include observing production lines, talking to frontline workers, and identifying i...read more

Inventory management is the process of overseeing and controlling the flow of goods from manufacturers to warehouses and from these facilities to point of sale.

• Inventory management involves tracking inventory levels, ordering and receiving goods, and managing stock levels to ensure optimal levels of inventory.

• Effective inventory management can help reduce costs, prevent stockouts, and improve customer satisfaction.

• Inventory management techniques include ABC analysis, just-in-...read more

Improving productivity can be achieved through effective time management, prioritization, delegation, and automation.

• Create a to-do list and prioritize tasks based on importance and urgency

• Delegate tasks to team members who are capable and available

• Automate repetitive tasks using technology

• Take breaks and avoid multitasking to maintain focus and energy

• Set realistic goals and deadlines

• Eliminate distractions and interruptions

• Invest in training and development to improve skills ...read more

SMED stands for Single-Minute Exchange of Die, a lean manufacturing technique to reduce setup time.

• SMED aims to reduce setup time to less than 10 minutes, ideally within a single digit minute.

• It involves separating internal and external setup tasks to streamline the process.

• Examples of SMED implementation include Toyota's production line where setup time was reduced from hours to minutes.

OEE stands for Overall Equipment Effectiveness, a metric used to measure the efficiency of a manufacturing process.

• OEE takes into account three factors: availability, performance, and quality.

• It is calculated by multiplying availability, performance, and quality percentages.

• For example, if a machine is available 90% of the time, operates at 80% of its maximum speed, and produces good parts 95% of the time, the OEE would be 68.4% (0.9 * 0.8 * 0.95).

Types of waste include overproduction, waiting, defects, excess processing, excess inventory, unnecessary motion, and unused talent.

• Overproduction: producing more than what is needed

• Waiting: idle time due to lack of materials, information, or equipment

• Defects: errors or mistakes that require rework or scrap

• Excess processing: using more resources than necessary to complete a task

• Excess inventory: having more inventory than needed

• Unnecessary motion: unnecessary movement of peop...read more

Lean tools are techniques used to identify and eliminate waste in a process to improve efficiency and quality.

• Value Stream Mapping: A tool used to visualize and analyze the flow of materials and information in a process.

• 5S: A method for organizing the workplace to improve efficiency and effectiveness.

• Kaizen: Continuous improvement through small, incremental changes.

• Kanban: A visual system for managing workflow and inventory.

• Poka-Yoke: Error-proofing techniques to prevent mist...read more