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Flashcards in Lean Quiz - Devall Notes Deck (21):
1

Standardization

current state definition of all system elements

2

Heijunka

scheduling mechanism controlling mix and leveling demand at single point in process
- also known as production smoothing

3

Kanban

method to allow material pull where one piece flow cannot work
- inventory and production control

4

Jidoka

machines that can detect and halt the process until a fix is made - build quality in station

5

Andon

ability of an operator to identify a defect - requires standard response for team

6

Quality at the source

MO CO MOO
no inspection

7

Continuous Improvement Cycle

credited to Schewhard
developed by Deming
PDCA (plan-do-check-act) - iterative 4 step management method for control and continuous improvement of processes/products

8

3 building blocks that shape committment to continuous improvement

challenge - long term vision
kaizen - cont. improvement
genchi genbutsu - go to source to find facts to make corrections

9

Ford - keys to success

- interchangable parts
- moving conveyor to bring car to employee
- specialized and balanced labor
- vertical integration

10

Ford - weakness of mass prod.

- limited goals
- end of line repair
- low employee morale
- dedicated machines only build 1 part
- low product variety
- low wage led to reduced turnover

11

GM perfects mass prod.

- product variety
- decentralization
- division of professional labor
- standardization of component parts

12

GM - still weaknesses

- no improvement of labor issue
- full of hidden waste

13

Mass production issues

- absenteeism
- work assignment restrictions
- lots of hidden waste
- holding back knowledge/effort

14

Sakichi Toyoda

- invented automatic power loom --- JIDOKA
- developed 5 Why Technique

15

Kiichiro toyoda

- implemented Chain Driven Assembly Line
- initial efforts for JIT

16

Eiji Toyoda

credited with JIT and Jidoka implementation

17

Taiichi Ohno

- defined 7 wastes - MUDA
- refined JIT with Kanban
- refined jidoka adding Andon

18

Shigeo Shingo

- developed SMED
- Poke Yoke - refined error proofing strategies

19

how to eliminate waste

in order to eliminate waste, you must set standards so that you know what your benchmarks for improvement are - must re-standardize continuously

20

TPS Lean House - most important aspect

- employee involvement

21

After Sales collapse, what did company agree to?

- lifetime employment
- wages tied to seniority
- wages tied to company profitability through bonuses