In lean systems, if a defective product is found, which of the following is generally not done?

Question

BlackTom AI · Accepted Answer

In lean systems, handling defects focuses on immediate containment, stopping or signaling the line when necessary, and preventing waste from propagating, rather than passing a bad unit along unchecked.
Option 1: 'The defective unit is passed on to the next workstation.' This is generally not done in lean practice because moving a defective part downstream propagates waste, increases rework, and can contaminate subsequent processes. It violates the core goal of stopping the defect chain.
Option 2: 'The production line is stopped.' In many lean contexts, when a defect is detected, the line is stopped (or a signal is raised) to contain the issue and investigate root causes (jidoka/poka-yoke style thinking). While not universal in all implementations, this is a common and accepted response to prevent further defects.
Option 3: 'The defective unit is returned to the worker responsible for creating the defect.' Assigning blame is not a primary lean strategy; instead, the focus is on correcting the defect and addressing root causes. Returning the defective unit directly to the same worker can be impractical and disrupt workflow, so it is generally not the standard approach.
Option 4: 'The production line is made aware of the problem without necessarily stopping the line.' Visual signals, alarms, or alerts are typical in lean environments to inform the team while the line continues operating if feasible, or to trigger containment actions without a full stop. This approach supports rapid response while maintaining throughput where possible.

In lean systems, if a defective product is found, which of the following is generally not done? Single choice

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