Lean Supply Chains - Chapter 14 Flashcards
(28 cards)
What is Lean?
lacking richness, sufficiency or productiveness
Where did lean thinking come from?
basis of lean thinking came from the Toyota Motors (Japan)
What is the TPS?
Toyota Production System
- was developed to improve quality and productivity.
What philosophies is TPS based on?
- Elimination of waste (main focus in OM)
- Respect for people
What does TPS elimination of waste include:
- Waste from overproduction
- Waste of waiting time
- Transportation waste
- Inventory waste
- Processing waste
- Waste of motion
- Waste from product defects
What is being “lean” about?
Being “lean” is about maximizing the value while minimizing wastes
Value
something for which the customer is willing to pay
Non-value-adding
these are activities that consumer resources and don’t directly satisfy customers
Waste
anything that doesn’t add value in the process
What kinds of wastes are there?
Defects
Overproduction
Waiting time
Non-used or Unused talent: Wastes from underutilization of the workforce
Transportation waste
Inventory
Motion waste: Wastes from unnecessary movements of people (workforce)
Extra- or Over-processing: Wastes from doing more work or having more things than required
What is lean production?
integrated activities designed to achieve high-volume production using minimal inventories
Lean production includes:
+ involves the elimination of waste in production effort
+involves the timing of production: Just in time production
Pull system
to start a new work or production only when there is an order.
- Lean production is based on the ‘pull’ logic that nothing will be produced until it is needed.
Push system
to start a new work or production in advance based on forecast
Lean Six Sigma
to combine quality control tools/ approaches of Six Sigma and the concept of lean manufacturing (reducing wastes and unnecessary costs)
What is lean service?
is to apply the lean principles and methods in the service industry
Lean service:
operates with greater uncertainty and variability that are much harder to control.
+ Uncertainty in service times (task times)
+ Uncertainty in demands (customer arrivals)
+ Uncertainty in customer contact & involvement
Kaizen
the Japanese philosophy that focuses on continuous improvement
Quality at the source
to do it right the first time at the source (manufacturing site); and if something goes wrong, the workers will stop the process immediately.
Workers role:
– Workers are personally responsible for the quality of their output
– Workers are empowered to do their own maintenance
– Workers become their own inspectors
Kanban
means “sign” or “instruction card”
– Cards or containers are used
– Kanban significantly reduces the setup cost
– Nowadays, companies use digital tools
Just-in-time (JIT) production
to produce what is needed when needed and nothing more (a pull system)
– Anything over the minimum is waste
– Ideal production and order size is one
– Often has multiple shipments per day
JIT and Zero inventory
inventory hides problems
– JIT exposes problems otherwise hidden by inventory
Value stream mapping (VSM)
a special type of flowchart tool to develop lean processes.
– Used to visualize product flows through various processing steps
– VSM focuses more on values and wastes; flowcharts focuses on the processes itself
