Unit 6: Lean Manufacturing Flashcards Preview

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Flashcards in Unit 6: Lean Manufacturing Deck (15)
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1
Q

What is lean production or JIT (just-in-time)?

A
Integrated activities 
designed to achieve 
high-volume, high-quality production using 
minimal inventories of raw 
materials, work-in-process, 
and finished good
2
Q

What is the Japanese approach to productivity? What are the seven elements that address the elimination of waste and are embodied in the Toyota Production system?

A

Lean Suppliers, lean procurement, lean suppliers, lean manufacturing, lean logistics, lean warehousing

3
Q

What are Kanban card sets? Work through the solution to Example 14.1 on page 362 of the textbook.

A

Kanban  A signaling device used to control production. Kanban pull system  An inventory or production control system that uses a signaling device to regulate flows.
[14.1] k = ​​  DL(1 + S)/   C
  ​​​​

4
Q

How is “respect for people” important in making the lean production system effective in organizations?

A

Respect for people encourages workers to improve productivity. Management views workers as assets, not as human machines

5
Q

What are the key factors in implementing lean production? Study Exhibit 14.7.

A

The concept includes the entire supply chain with the goal of creating value for the customer by eliminating all non–value-adding activities and waste

6
Q

What is the relationship between lot size and setup costs under a lean production system? See Exhibit 14.10, which is discussed under Minimized Setup Times on page 363.

A

As lot size is decreased in a kanban approach, set up cost is also decreased. The setup time is decreased by dividing it into internal (done while machine is running) and external activities (done while machine is stopped)

7
Q

What is value-stream mapping and how is it used? It is not required to memorize VSM symbols.

A

Value stream mapping is a flowcharting tool used to visualize flows through a process.
∙ Features of the tool are the identification of value adding and non–value-adding activities, together with a time line for each activity and the process as a whole.
∙ The tool can be applied to production, logistics, and distribution processes.
∙ The goal in using the tool is to identify ways to “lean” a process by eliminating waste and creating value for the customer.
∙ A Kaizen event is a short-term project designed to quickly improve a process.

8
Q

What is the relationship between total quality control and lean production?

A

Quality at the source -   The philosophy of making workers personally responsible for the quality of their output. Workers are expected to make the part correctly the first time and to stop the process immediately if there is a problem.

9
Q

How can lean production be applied to services? What are some of the more successful lean techniques as detailed on page 364-366?

A

1) Organize problem solving groups
2) Upgrade housekeeping
3) Upgrade quality
4) Clarify process flows
5) Revise equipment and process tech
6) Level the facility load
7) Eliminate unnecessary activities
8) Reorganize physical configuration
9) Introduce demand Pull Scheduling
10) Develop supplier networks

10
Q

Lean Suppliers

A

Lean suppliers are able to respond to changes. Their prices are generally lower due to the efficiency of lean processes, and their quality has improved to the point that incoming inspection at the next link is not needed. Lean suppliers deliver on time and their culture is one of continuous improvement. To develop lean suppliers, organizations should include them in their value stream planning. This will help them fix problems and share savings

11
Q

Lean Procurement

A

A key to lean procurement is automation. The key to lean procurement is visibility. The overlap of these processes needs to be optimized to maximize value from the end-customer perspective.

12
Q

Lean Manufacturing

A

Lean manufacturing systems produce what the customers want, in the quantity they want, when they want it, and with minimum resources.

13
Q

Lean warehousing

A

This relates to eliminating non–value-added steps and waste in product storage processes.

Waste can be found in many warehousing processes including shipping defects, which creates returns; overproduction or overshipment of products; excess inventory, which requires extra space and reduces warehouse efficiency; excess motion and handling; waiting for parts; and inadequate information systems

14
Q

Lean Logistics  

A

Lean concepts can be applied to the functions associated with the movement of material through the system. Some of the key areas include optimized mode selection and pooling orders; combined multistop truckloads; optimized routing; cross docking; import/export transportation processes; and backhaul ­minimization

15
Q

Lean customers

A

Lean customers have a great understanding of their

business needs and specify meaningful requirements.