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ETH: Production and Operations Management > Lecture 11: Performance improvement > Flashcards

Lecture 11: Performance improvement Flashcards

1
Q

Name frameworks to assess operational improvement and excellence. (3)

A

BEF
Baldrige Excellence Framework

EFQM
European Foundation for Quality Management

Shingo
Prize for Operational Excellence

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2
Q

What are different types of production systems? (2)

A

Company-specific
production system
(customized Systems)

Off-the-shelf
production systems are
(available pre-built systems)

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3
Q

What are advantages and disadvantages of Off-the-Shelf Models? (4)

A

Advantages

  • Cost-Effective
  • Quicker Implementation

Disadvantages

  • Lack of Customization
  • Limited Scalability
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4
Q

What is the biggest challenges for the implementation of a company-specific production system (XPS)?

A

To sustain senior and middle management’s commitment

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5
Q

What are the two pillars of the Toyota Production System (TPS)?

A
  1. Just-in-Time (JIT): producing only what is needed, when it is needed
  2. Jidoka: refers to the ability of processes to detect abnormalities and automatically stop
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6
Q

Explain „Jidoka“!

A

Stop & fix the Problem

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7
Q

What means „Kaizen“?

A

“change for the better”
or
“continuous improvement.”

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8
Q

What are the five significant cultural aspects of the Toyota Way? (5)

A
  1. Continuous Improvement (Kaizen)
  2. Respect for People
  3. Teamwork and Collaboration
  4. Long-Term Thinking
  5. Genchi Genbutsu: “go and see for yourself“
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9
Q

What are the five principles of lean, also known as the Toyota Way principles? (5)

💰🏄‍♂️🚀

A
  1. Value: Specify customer value.
  2. Value Stream: Identify the value stream (product-process design, layout decision).
  3. Flow: Ensure a smooth and uninterrupted flow of work. Jidoka ans JIT are enemies oder Flow
  4. Pull: Implement a pull production.
  5. Continuous Improvement: Foster a culture of continuous improvement, also known as Kaizen.
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10
Q

What do you need to do to improve flow? (3)

A

Eliminate ..

  • Muda: Waste, Inefficiency
  • Mura: Unevenness, Variability
  • Muri: Overburden, Strain
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11
Q

What does Muri, Mura and Muda mean?

A
  • Muri – Overburden (Überlasten) (waste due to the poor design)
  • Mura – Unevenness (imbalance due to poor implementation of the design)
  • Muda – Waste
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12
Q

What are the seven wasters? Which one is the worst?

A
  1. Transportation
  2. Inventory
    _
  3. Motion
  4. Waiting
    _
  5. Overproduction
  6. Over-processing
    _
  7. Defects
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13
Q

Name five methods and tools to
institutionalize improvement routines! (HIDDA)

A

H oshin Kanri (shared vision)
I mprovement Boards and Meetings (visual)
D aily Layered Accountability
D aily Kaizen Activities and Kaikaku Projects
A3 Management (problem solving)

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14
Q

What are the four steps of Jidoka?

A
  1. Discover abnormalities
  2. Stop the process
  3. Fix the problem
  4. Investigate and solve the root cause
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15
Q

What does Poka-Yoke? (2)

A

Mistake proofing, prevents defects by

  • preventing,
  • correcting,
  • drawing attention to

human errors as they occur.

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16
Q

What are the 3 Poka Yoke mechanisms?

A

Contact
Method based on physical attributes (the product’s shape Kaikaku Projects .: O2 connectors)

Fixed-Value
Method based on number of movements (e.g. number of screws: Only 8 screws if you need 8 screws)

Motion-step
Method based on sequence of events (e.g. correct assembly order: Money after bank card removal)

17
Q

Why is Poka Yoke important? (3)

A
  • Eliminates mistakes
  • Ensures that processes work right the first time
  • Improves quality and reliability
18
Q

What are the three guiding questions before implementing Poka Yoke?

A
  • What is the cause of the defect?
  • Is there an easy way to prevent the defect from occurring?
  • In the event of a defect, how can it be detected and controlled?
19
Q

What is 5S?

A

Workplace organization concepts

20
Q

What do the 5s stand for? Explain!

A

Seiri = “Sort”

  • Needed things.
  • To sort things at your workplace by deciding what is actually needed

Seiton = “Set”

  • Order things for time.
  • Order things in the workplace to reduce time spent on non-value added activities searching for items, tools and documents

Seiso = “Shine”

  • Clean.
  • To clean the workplace.

Seiketsu = “Standardize”

  • To maintain the first three pillars by creating a consistent approach to completing tasks.

Shitsuke = “Sustain”

  • To maintain the previous 4S and make a habit of maintaining correct procedures.
21
Q

What is 5S used for? (3)

A

Used to create an efficient and attractive workplace that:

  • Eases communication
  • Helps to focus kaizen
22
Q

What does it result in (indirectly)? (3)

A
  • Safety
  • Quality
  • Productivity
23
Q

Name three problem solving methods!

A
  • PDCA method (Plan-Do-Check-Act) or PDSA (Plan-Do-Study-Act)
  • DMAIC model (Define, Measure, Analyze, Improve & Control)
  • 8D-Problem Solving (“Eight Disciplines”)
24
Q

What are the process phases for 8D vs PDCA & DMAIC problem-solving approaches?

A
25
Q

What is 8D using in the identification of root causes?

A

● Statistical methods

26
Q

What does TRIZ 🌟 mean?

A

The Theory of Inventive Problem-solving

27
Q

What do you have to do according to TRIZ to be innovative and creative?

A

Follow structured and systematic approaches

28
Q

What is the TRIZ problem-solving approach? 🌟 (4)

A
  • Identification
    of a specific problem
  • Reduction
    of problem to TRIZ database of general problems
  • Matching
    the problem with available general solutions from TRIZ
  • Development
    of a particular solution tailored to your needs
29
Q

What types of contraindications are available according to TRIZ? Explain! (2)

A

Technical contradictions
When one aspect improves, the other declines

Physical contradictions
When there are contractions to the physical properties and performance of a product

30
Q

What is A3?

A

Reporting template by Toyota

31
Q

What can it be used for? (2)

A
  • problem-solving
  • project reporting
32
Q

Name 3 reasons why A3 is popular?

A
  • Simple
  • Encourages to be short
  • Encourages to visualize data
33
Q

Name two times when you should use A3!

A

● Complex problems
● Data for future use

ETH: Production and Operations Management (12 decks)

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