Lean Consultant

Lean Consultant Interview Questions and Answers

Updated 22 Aug 2024

Q1. What are the different lean tools that are being implemented at the shop floor ?

Ans.

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

Q2. What is 5-S and explain the different S ?

Ans.

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

Q3. What is heat treatment process ?

Ans.

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

Q4. What is thumb rule for cycle time and lead time

Ans.

Cycle time is the time taken to complete a task, while lead time is the total time taken from request to completion.

Cycle time is the time it takes to finish a task from start to end.
Lead time is the total time taken from the request for a task to its completion.
A general rule of thumb is that cycle time should be shorter than lead time for efficient processes.
For example, if the cycle time for manufacturing a product is 2 hours, but the lead time from order to delivery is 5 ...read more

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Q5. what is Line balancing

Ans.

Line balancing is the process of assigning tasks to workstations in a way that evens out the workload and maximizes efficiency.

Involves distributing work evenly among workstations
Helps in reducing idle time and bottlenecks
Improves productivity and efficiency
Example: In a manufacturing plant, line balancing ensures that each workstation has a similar amount of work to do, preventing delays and optimizing production

Q6. what is Gemba walk ?

Ans.

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

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Q7. What is SMED ?

Ans.

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.