10.2 Flashcards
lean production
approach that aims to eliminate waste in manufacturing, considering the process and product as an ongoing system and not a one off task. emphasises continuous improvements and creates a culture of problem solving within the whole organization
5 characteristics of lean production
just in time supplies/systems – getting materials when needed, based on demand (pull)
zero inventory
multi skilled, highly trained workforce
quality control, continuous improvement
zero defects
list some lean production principles
minimising inventory
eliminating waste
max production flow
pull production
partnering w suppliers
empowering workers
kaizen
kaizen
all involved are striving for continuous improvement
lean production advantages
increases product quality
increases productivity
can lead to competitive advantage
can improve employee working conditions
reduced environment impact due to reduced waste
lean production disadvantages
often high capital costs bcs need to invest in JIT systems
no inventory to rely on
if breakdown occurs whole system can be halted
difficult to introduce to existing workforce (some may resist changes)
industries likely to benefit from lean production
manufacturing – extremely efficient production process. less waste and more time and money
construction – can minimise waste and optimise timelines
healthcare – can reduce wait times, save costings, provide good care for patients
industries not likely to benefit from lean production
industries w highly complex, low volume production – if waste is already at a minimum or parts cant be standardised
retail – back end can benefit, but stores and selling will struglle to implement due to wide range of customers
financial services – difficult as there is no physical product, + need to respond quickly to constantly changing market
value stream mapping
lean production tool used to analyse processes from production to delivery to customer. helps identify value and waste in production process
workflow analysis
the review of processes in a workflow, eg identifying potential areas for imporvement within production line
what does value stream mapping focus on
the bigger picture of the production process, across entire value chain. aims to identify areas for improvement, optimise overall
what does workflow analysis focus on
details of the production line. worker movements can be analysed, helping identify source of faulty product quickly. aims to imrpobe efficiency
product family
group of products having common classification criteria
product family advantages
reduced design effort
less manufacturing processes
smaller number of suppliers needed
waste from one product can be used to manufacture another
easily adapt production to meet demand for particular family member
list 3 important elements of a workforce
training
devolution
kaizen
