PBM & Lean
This concept defines creating what the customer wants—and eliminating what doesn’t
What is Value
Value Stream Mapping is a visual tool that shows the flow of materials and information from ______ to ______
What are Supplier and Customer
T or F: Standard work is the best-known method for executing a task, documenting the precise sequence and timing needed to match demand
What is True
A visual system used to identify waste in a process
What is Value Stream Mapping
Understanding the flow of work through a system of process steps allows you to do this
What is Control your WIP
In PBM and Lean alike, this shared belief holds that people—not processes alone—are the primary drivers of improvement
What is Respect for People
This type of time represents steps that make the product valuable from the customer's perspective
What is Value-Adding Time
T or F: Defining the best practice for tasks to maintain a consistent speed (Takt time) throughout the system is Standard Work
What is True
Startup, shutdown, and abnormal steps executed in correct sequence to avoid unsafe deviations
What is Standard Work
This mathematical law states that the average number of items in a system equals their average arrival rate multiplied by their average time in the system
What is Little's Law
It proves that if your throughput stays the same but you add more WIP, your lead time must go up. It’s a powerful tool for predicting delivery dates without complex estimation
PBM emphasizes comparative advantage; Lean emphasizes this by enabling people closest to the work to perform it
What is optimizing Flow at the source
Value Stream Mapping should be done by a group of people from different departments, known as this
What is a Cross-Functional Team
This establishes a stable, repeatable, and documented method, comprising Takt time, sequence, and standard WIP, to meet customer demand efficiently
What is Standard Work
Highly efficient filter swaps and maintenance executed repeatably with reduced exposure
What is SMED
This term refers to the mental cost incurred when a worker is forced to stop one WIP task and start another before finishing
What is Switch-tasking
Research shows that multitasking can reduce productivity by up to 40%. In Lean, we limit WIP specifically to keep us focused on one high-value task at a time, ensuring it gets "Done" faster
PBM encourages the challenge process to find root cause; Lean operationalizes this by repeatedly asking this famous question
What is Why (5-Why's)
According to lean methodology, this is the first and most foundational step in creating value stream thinking
What is defining value from the Customer's perspective
Person accountable for regularly inspecting and verifying adherence to the standard using a checklist or other novel approach (1-on-1)
Who is the Team Leader or Front-Line Supervisor
Use this to reduce in-process inventory and lower induction consequences
What is WIP Limits
This metric is the ratio of actual working time to the total lead time, which improves as WIP is properly controlled
What is Flow Efficiency
Controlling WIP reduces "wait time," boosts flow efficiency and allows the team to be much more responsive to customer demand
In PBM and Lean, leaders are expected to do this before redesigning or improving processes
What is Go and See (Gemba)
The three distinct types of activities tracked in a value stream: Value-Added, Non-Value-Added, and this kind of activity
What is Necessary or Required tasks
Standard Work in TBM can be characterized with these 3 things to ensure consistency and minimal waste and variation
What is: pace of demand (Takt time), the sequence of steps, and necessary inventory (full kit)
Heat exchanger fouling or compressors limiting production rate a called this
What is a Bottleneck
This four-word mantra is used by Lean teams to remind members to finish current tasks before picking up new ones
What is "Stop Starting, Start Finishing"