Lean Flashcards
What is lean and its 2 base pillars?
On-the-job learning method based on;
Continuous improvement:
-Learning by taking small steps
-Testing changes to determine the effectiveness
Respect:
-Understand the challenges of each person
-Support their development to utilise their abilities
What are the 5 principals of lean?
1:
-Value specified by the customer only
2:
-Series of activities converting raw material into the product
-Lean analysis minimises non-value adding activities & breaks down the process into separate groups
3:
-Customer requirements dictate the rate at which products flow on a production line
-Aim to only have processes that are value added
4:
-Without bottlenecks & queuing, caused as whole batches are processed individually then advance to the next step
-pull-signals eliminate stacking
5:
-Perfection in all aspects: products, production, training and team dynamics
What are the 8 types of waste in lean?
1) Scrap & rework:
-Repetition or correction of a process (Not correct on the first attempt)
2) Inventory:
-No value holding large quantities of: Raw materials, Work in progresses or finished goods
3) Overproduction:
-Faster, sooner or more than the customer(s) needs
4) Motion:
-Unnecessary movement of people, parts or machines within processes
5) Processing (over-processing):
-Beyond the standard required by the customer
6) Transportation:
-Unnecessary movement of people or parts between processes
7) Waiting:
-People or parts waiting for a work cycle
8) Under-utilised people:
-Waste of untapped potential
What are the 7 approaches in lean as a toolkit?
-Workplace organisation (5S)
-Process mapping
-Kaizen
-Performance monitoring
-Visual tools & controls
-Reducing inventory
-Root cause analysis
Explain the ‘5S’ lean toolkit approach
Sort:
-Remove everything not frequently needed to store rooms
Straighten:
-Locate what remains in the best place (inventory footprints, trolleys, ect)
Sweep:
-Frequent tidying & cleaning (checking)
Standardise:
-Standardise & failsafe work whenever possible
Self-discipline:
-Everyone participates in 5S (regular audits)
Explain the ‘Process Mapping’ lean toolkit approach
-A process map documents flow of material & information in a process
-Identifies bottlenecks & queues in industrial & office processes
-Based on real (collected) data
-Staff are involved within the process & mapping
Explain the ‘kaizen’ lean toolkit approach
-Small continuous incremental improvements
-Workers acknowledged as process experts
-Workers in grouped teams
-Time allocated for kaizen
Plan:
-How to implement change
Do:
-Apply the change
Study:
-Study the results of the change
Act:
-If improved method, then adopt the procedure as standard
Explain the ‘Performance Monitoring’ lean toolkit approach
-Monitor at all stages of production of goods/services
Display results for the team, helps understand the project health;
-Is the process working?
-Where are the weak areas?
-What stages can be improved?
Explain the ‘Visual Tool & Controls’ lean toolkit approach
People:
-Charts for worker responsibilities, tasks & expectations
Training:
-Pre-planned training matrix to demonstrate expected future development of workers
Inventory:
-Markers showing where inventory received, progressed & completed
Tools:
-Visual indication where tools & jigs are to be stored (eg. shadow boards)
Results:
-Performance displayed at prominent places (eg. lead time, tock turn, right first time rate, unit cost, total output)
Processes:
-Aids & diagrams with process-related information (eg. maintenance (machinery) status & performance)
Why use ‘Visual tools & controls’ in lean (toolbox)?
-Staff understand current efficiency of the plant & how it works
-Are staff adequately trained?
-Wat/who are the weak links?
Explain the ‘Reducing inventory’ lean toolkit approach
Aim to minimise the following:
-Cost of production (over-production)
-Work in progress or completed work being stored
-Value of stored raw material
-Cost of floor space to store surplus inventory
-Cost of finance for surplus
SUPPLY CHAIN MUST REMAIN SECURE
Explain the ‘Root cause analysis’ lean toolkit approach
-Identify root cause of an issue by working backwards
‘5 Whys’ approach:
What shows a workplace is lean?
-Control boards (for operation & organisation)
-“just in time” supply (low inventory)
-One piece flow (trolleys not forklifts)
-Quick changeover (“single minute exchange of dies”)
-Even, levelled production
-Pull systems using communication devices (“KANBAN cards”)
-Overall equipment effectiveness measurement (no overburden)
What are control boards in the lean workplace model?
-Controls and evaluates the process
-Involves team with the product
subjects:
-Delivery performance
-Non-conformance record
-Lead time
-Training
What is “just in time” supply (JIT) in the lean workplace model?
-Little to no held inventory
-Flexibility (control of variants)
-Single piece flow (small batch delivery)
-Local supply chain (ideally)
-Co-located suppliers (manufacture and assemble at same/close site)
