11- Lean synchronization

Question 1

What are lean synchronization principles?

Answer 1

To deliver outputs JIT so as to elliminate waste completely and meet demand perfectly.

Question 2

Compare traditional vs lean synch approach.

Explain boat analogy

Answer 2

traditional approach: operations and processes are separated by buffer inventories. Problems are difficult to identify and there is interrupted flow.

lean synch approach: all processes deliver output to next stages JIT. Easy to identify problems and better chances of solving them

Question 3

What are the barriers to lean synch?

Answer 3

-failure to elliminate waste
-failure to involve everyone in this approach
-failure to set improvement as continuous activity.

Question 4

Explain the dfferent types of waste

Answer 4

-waste due to irregular flow
-waste due to inexact supply
-waste due to low flexibility
-waste due to variations in the process

-Muda:waste of resources
-Mura: waste due to over/underloading
-Muri: waste due to irregular flow

Question 5

How can you elliminate each waste type?

Answer 5

-streamline the flow
-match demand exactly
-increase flexibility
-decrease variability in the process

Question 6

How can you streamline the flow?

Answer 6

-ensure visibility to identify potential improvements. Good to use visual and colorful systems (kanbans)
-set smaller scale technology preferred multiple smaller machines rather than few large ones
-identify value adding and non value adding activities with VSM (Value Stream Mapping) , that maps production path from start to finish

Question 7

how can you match demand exactly?

Answer 7

using pull control. It consists in only supplying when the final customer requests demand. An example of pull control is the Kanban’s method.

Question 8

how can you increase flexibility?

Answer 8

by reducing set up times

Question 9

how can you minimize variations in the process?

Answer 9

-level the scale: reduce batch sizes but increase amount of batches.
-level the delivery schedules: deliver small quantities of different products in a same truck, and send higher frequency of trucks.
-adopt mixed modelling:
-adopt TPM (Total Productive maintenance): involve everyone in search for maintenance improvements and elliminate variability from breakdowns

Question 10

How can you overcome involvement barrier?

Answer 10

by setting involvement as a continuous activity and move closer to ideal state.
train basic-working practices like: discipline, flexibility, equality, autonomy…

Question 11

How can you set continuous improvement path?

Answer 11

continuous improvement allows to have lower throughput times + high utilization levels. In the end, it overcomes the tradeoff and it is achieved by reducing process variability.

GRAPH!