Lean Flashcards
What is lean
What is waste
Different type of waste
method
waste minimization without sacrificing productivity within a manufacturing system
Waste: step or action in a process that is not required to complete a process successfully
I RMW produces transportation over processing
Inventory
Rework from defect
Motion
Waiting
Over production
Transportation
Over processing
Jit
Pre request for implementation of jit
System whose objective is to produce or to procure products or components as they are required by a customer or for use, rather than for stock
Just-in-time production:
component on a production line is produced only when needed for the next stage
Just-in-time purchasing:
material purchases are contracted so
that the recast and usage of material to the maximum extent possible, coincide
Prerequisites
1: exact date exact time
2: straight dilvery
3: visit of engg
4: edi
Main features of jit
M E C pillera alambe so careful select
labour
1: Material - handling cost are reduced.
2: eliminating defects as quickly as possible
3: customer demand faster.
4: carefull select the supplier
5: labours idle time get reduced
Essential pre requisite of a jit system
V Guard Low Demand ola DTP
Low variety of goods
Vendor reliability
• Good communication
. Demand stability
TOM
Defect free materials
Preventive maintenance
Impact of jit system
Pow
Product pricing
Overhead cost
Waste costs
Back flushing and the problem
How to over the problem
no data entry of any kind until a finished product is completed
total amount finished is entered into the computer system, which multiplies it by all the Components listed in the bill of materials for each item produced. This yields a lengthy list of ponents that should have been used in the production process and which are subtracted from he beginning inventory balance
Problem: SLIP
Production reporting
Lot tracing
Inventory accuracy
Scrap reporting
Solution for problem
moving a few
reliable employees into these positions
have an experienced shift supervisor to collect this information
success of a back-flushing system is directly related to a company’s willingness to invest in a well-paid experienced well-educated production staff that undergoes little turnover.
Kaizen coasting
Its aim
Principles
Continues improvement
small, incremental changes routinely applied and sustained over a long perfod result significant improvements
aims to involve workers from multiple functions and levels in the organization in working together to address a problem or improve a particular process
Principles
G N Fuck SEC
1:gradual improvements in the existing situation,
2: It encourages collective decision making and application of knowledge.
3: There are no limits to the level of improvements that can be implemented.
4.Kaizen involves setting standards and then continually improving these standards to achieve long-term sustainable improvements
5:The focus is on eliminating waste, improving systems, and improving productivity.
6:Involves all employees and all areas of the business]
5s
workplace organization method
work space should be organized for efficiency and effectiveness
sort”, “set in order”,
“shine”, “standardize”, and “sustain”
Or
seiri, selton, seiso, seiketsu, and shitsuke
Tpm
Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of production and quality systems
TPM helps in keeping all equipment in top working condition so as to avoid breakdowns and delays in manufacturing processes.
8 pillers of tpm
A F P EQEO S
1: autonomous maintenance:
Active employee participation
2: focused improvement:
Minor improvement made on continuous basis
3: planned maintenance:
Proper maintenance system
4: early management:
Shorting the time required for product development
5: quality maintenance:
Achive custom satisfaction
6: education and training:
Improve knowledge and skill
7: office tpm:
Tpm technique in administration
8: safety health and environmental:
Safety if workers is utmost importance
Performance measurement in tpm
Overall equipment effectiveness
Availablity x performance x quality= OEE
Six big losses are
1: equipment failure or breakdown
2: setup or adjustment
3: idling and minor stoppages
4: reduced speed
5: reduced yeild
6: quality defects and reworks
World class performance: 85%
Oee greater than 50% is more realistic
Six Sigma and primary focus
quality improvement technique whose objective to eliminate defects in any aspect that affects customer satisfaction
Primary focus:
PM Decide to collaborate the goal of customer
1: Proactive management team.
2:Management, improvements, and processes
3:Decisions based on data-driven facts.
4:Collaboration with in the business
5:Goal for perfection
6:Customer satisfaction
Implementation of six sigma
2 type
1: DMAIC
2: DMADV
DMAIC and it 5 phase
It is used to improve existing business process
1:Define the problem, the project goals and customer requirements.
2: Measure the process to determine current performance.
3: Analyze the process to determine root causes of variation and poor
performance (defects).
4:Improve the process by addressing and eliminating the root causes.
5:Control means maintaining the improved process and future process performance.
Under what circumstances DMAIC be used
CA CB TOES
CA: competitor’s action are stable
CB: competitors behaviour is unchanging
T: technology is stable
O: project on a ongoing continue improvement process
E: A product or process exist
S: only a single product need to be altered
