06: Lean Production Flashcards
Toyota Production System:
overarching philosophy
+ inventor
+ 4-fold slogan
+ seminal book
1 goal, 2 pillars & 3 bases (temple metaphor):
- lean production
- Taiichi Ohno
- “Produce only
1. what is needed,
2. at the time it is needed
3. at the right quality,
4. in the right quantity”
- “Produce only
- “The machine that changed the world”
=> analysis by Womack, Jones & Roos, not by Taiichi Ohno - “temple”
goal:
Highest Quality, Lowest Cost, Shortest Lead Time
just in time respect for ppl
————————Standardised work———————-
——————Continuous improvement——————
————Stability, Orderliness and Evenness———-
Batch production n lean:
Don’t go together
5 (sequential) lean principles + 2 focus points
5 (sequential) lean principles:
- Specify value from standpoint of end customer
- eliminate all waste, keep only value creating steps
- => value stream mapping*
- steps in tight sequence so product will flow smoothly
- let customers pull value
- Continuously improve the processes
2 focus points:
- Quality at the source
- Focus on cycle time
Kanban :
Def + typical choice
Result
- Signal to produce =(often) empty inventory at next stage
- > single piece flow
Kanban: def
example w result
signal to work eg when next Work In Progress inventory is empty >>> single piece flow
Lean: origins & fundamental book
- builds on 100 ys of development
- books: “the machine that changed the world” 1990
(+ other book by Taiichi Ohno)
Toyota vs all other producers in the 1990s
(4 production factors + 2 results + 1 basic principle)
Toyota used half of all others:
- 4 ways
- half inventory,
- half production space,
- half effort,
- half investment
- 2 results
- produced faster
- w high quality!
- 1 basic principle
- total elimination of waste
list & explain 9 Lean buzzwords chosen by Professor
3 production design principles:
- Just-in-time = “right part at right time in right amount”
- Heijunka = balanced mixed production schedules
- Muri-Mura-Muda = no overburden, unevenness, waste
3 visualization techniques:
- 5S = sort, set in order, shine, standardize, sustain
- Kanban = “billboard” pull signal to produce (ROL)
- Andon = chord/signal to stop line, not pass on bad Q
3 error handling thecniques:
- Jidoka = in-process fault correction
- Poka Yoke = error-proofing behavior shaping constraints
- 5x why = get to root cause of problem
lean program / XPS def=
+ philosophical consideration
mgmt program / Co.-specific production system
using some (but maybe not all) principles & tools
Toyota
some say that lean production can be applied everywhere, but in reality not all of its principles fit every situation (esp. JIT)
Ohno’s 7 muda wastes
+ goal
T.i.m.W.o.o.d.
- Transportation
- Inventory
- Motion
- Waiting
- Overproduction
- Over-processing
- Defects (eliminate at origin)
=> smooth flow
