5.3 Lean production and quality management Flashcards
What is “lean production”
Lean production is all about decreasing waste (raw materials, labour, skills, time, space)
Production which involves getting the most out of the inputs for the least amount of costs and waste.
What are some advantages of mass production?
- High levels of stock
- Flow production
- Quality inspection
- Low skill level of work force
- Large-scale deliveries
- Higher economies of scale
What are some advantages of lean production?
- Reduced stock levels - JIT
- Adaptable
- Inbuilt defect prevention
- Highly skilled workers
- Small-scale deliveries
- Lower economies of scale
What is the definition of “kaizen”?
“the process of achieving continuous improvements in the workplace through workers regularly finding small ways of improving what they do”
What are some advantages of “kaizen”?
- When first introduced improvements in productivity of 30% or more are not uncommon
- It helps lower the break-even point
- It helps eliminate waste
- It helps management become more attentive to customer needs
- Applied to any work place owing to its simple nature and low day-to-day cost
- Improves safety and employee morale
What are some disadvantages of “kaizen”?
- Some staff may be unhappy or unwilling to get involved
- Can be tricky to implement
- The cost of setting up can be a problem
What is “Just-In-Time” (JIT)?
Just in time is a “pull” system of production. Actual orders provide a signal for when a product should be manufactured. Demand-pull enables a firm to produce only what is required, in the correct quantity and at the correct time.
Therefore there is very low stock levels of raw materials, work in progress and finished goods. This requires a carefully planned scheduling and flow of resources. Often using sophisticated scheduling software to plan production for each period of time, including ordering the correct stock.
Goods are received from suppliers only when they are needed.
What is a “Kanban” system?
A kanban system is a means to achieve Just-in-time (JIT production). IT works on the basis that each process on a production line pulls just the number and type of components the process requires. The mechanism used is a Kanban card, but usually a physical card but other devices can be used.
Kanban is a signalling system between different steps in the production process with the goal of creating a steady flow and reduce waste of time and resources.
What is an “Andon” cord?
The Andon cord is literally a cord that workers can pull - a cord they should pull - any time something in the manufacturing process goes wrong that would compromise the quality of the product or safety of the people. The line stops immediately and everyone’s attention is turned to the problem.
Acts as a signalling system showing the “health status” of the production process. Notifies people when a problem occurs.
What is “Quality Assurance”?
checks are completed at the end of each stage
What is “Total Quality Management” (TQM)?
everyone is responsible for the quality of the product. Employees are responsible for checking their own quality but also the previous work completed.
What is “Quality control”?
checks come at the end of the process. Often with a quality control inspector, they are specialised in checking for the quality of the product
What are “Quality circles”?
they are like a problem solving task force. The best will have employees from all areas and levels of hierarchy in the business
–> improves the quality in the organisation
A group of workers that meet regularly to identify and solve problems the business may be facing.
What is “Benchmarking”?
comparing with the best in the industry
What are some advantages of “benchmarking”?
By observing good practice elsewhere, a firm can learn how to improve its own systems and procedures
Clear and attainable targets can be set, based on the experience of others
Reduces the cost and wastage of performing unnecessary activities
