Midterm 1 Flashcards
Review for Midterm (44 cards)
Andon
a visual management system that signals issues in a production line so that problems can be addressed immediately, and empowers operators to stop the production process
Bottleneck Analysis
Identify which part of the manufacturing process limits the overall
throughput and improve the performance of that part of the process.
Continuous Flow
Manufacturing where work-in-process smoothly flows through
production with minimal (or no) buffers between steps of the manufacturing process.
Countermeasure
an action taken to address a problem in the production line. Countermeasures are used to address immediate symptoms while a root cause analysis is conducted.
Gemba
Japanese term that means “actual place” or “the place where value is created”
A philosophy that reminds us to get out of our offices and spend
time on the plant floor
Genchi Gembutsu
Japanese phrase that means “go and see”, observe the process
Hansei
Japanese word that means “self-reflection” or “introspection”
Heijunka
a Japanese word that means “leveling”. It’s a lean manufacturing technique that involves producing goods based on customer demand, rather than in batches. Purposely manufactures in much smaller batches by sequencing (mixing) product variants within the same process.
Jidoka
Japanese word that means “automation with a human touch”, Autonomation,
Design equipment to partially automate the manufacturing process (partial automation is typically much less expensive than full automation) and to automatically stop when defects are detected.
Just-in-Time (JIT)
a manufacturing system in which materials or components are delivered immediately before they are required in order to minimize inventory costs. Pull parts through production based on customer demand instead of pushing parts through production based on projected demand. Relies on many lean tools, such as Continuous Flow, Heijunka, Kanban, Standardized Work and Takt Time.
Kaizen
a Japanese business philosophy of continuous improvement of working practices, personal efficiency, etc.
Muda
Japanese term for waste. Anything in the manufacturing process that does not add value from the customer’s perspective.
Mura
Japanese term that signifies inconsistency or unevenness or variation in operations
Muri
Japanese term that signifies strain or overburdening, particularly of people or equipment, unreasonableness or absurdity
Poka-yoke
a Japanese term that means “mistake-proofing” or “error prevention”. It’s a system that helps prevent human error by correcting or highlighting mistakes as they occur
Takt Time
a calculation of the available production time divided by customer demand, The pace of production
Total Productive Maintenance (TPM)
A holistic approach to maintenance that focuses on proactive and preventative
maintenance to maximize the operational time of equipment. TPM blurs the distinction between maintenance and production by placing a strong emphasis on empowering operators to help maintain their equipment.
Kanban
Pull system. A method of regulating the flow of goods both within the factory and with outside suppliers and customers. Based on automatic replenishment through signal cards that indicate when more goods are needed.
Root Cause Analysis
A problem-solving methodology that focuses on resolving the underlying problem instead of applying quick fixes that only treat immediate symptoms of the problem. A common approach is to ask why five times – each time moving a step closer to discovering the true underlying problem.
Single Minute Exchange of Die (SMED)
Reduce setup (changeover) time to less than 10 minutes. Techniques include:
* Convert setup steps to be external (performed while the process is running)
* Simplify internal setup (e.g. replace bolts with knobs and levers)
* Eliminate non-essential operations
* Create standardized work instructions
Standardized Work
Documented procedures for manufacturing that capture best practices (including the time to complete each task). Must be “living” documentation that is easy to change.
Autonomous Maintenance
A method from TPM (Total Productive Maintenance) for engaging operators to carry
out basic maintenance activity (such as cleaning, lubrication, and inspection activity).
5S
Organize the work area:
* Sort (eliminate that which is not needed)
* Set In Order (organize remaining items)
* Shine (clean and inspect work area)
* Standardize (write standards for above)
* Sustain (regularly apply the standards)
Toyota Production System (TPS)
A manufacturing strategy developed by Toyota Motor Corporation of Japan over a
period of many years. TPS focuses on the complete elimination of waste from the manufacturing process, and is the progenitor of lean manufacturing.
