5.3 - Lean Production and Quality Management (HL - Unit 4) Flashcards
Lean Production
Producing efficiently and minimizing wasted resources whilst maintaining high-quality
Types of Wastes
- Transportation costs
- Movement of people
- Holding too much stock
- Waiting time in production
- Too much complexity (overprocess)
- Defect products
- Overproduction
Ways to Increase efficiency (ratio of output to input)
- Improve EE’s skills
- Improve motivation
- Better technology
- Better management
Continuous Improvement (Kaizen)
A philosophy whereby all EEs contribute to improving the production process
Just-in-time (JIT)
- Stock control method
- Inputs arrive just before they are used in the production process
- Finished products are delivered as soon as they are produced
Pros of JIT
- Hold less stock - reduced opportunity cost, more factory space
- Stock does not become outdated
- Can respond to the market quickly
- Motivated staff - job rotation and enrichment
Cons of JIT
- Entirely dependent on suppliers
- Higher delivery costs and less bulk buying
- Need to purchase and maintain IT
- Loss in reputation if unable to meet orders
Cradle to Cradle
- Production techniques that are efficient
- But also waste-free and sustainable
Quality Control
Inspection of the product or service (or a sample)
Impact:
- Negativity amongst staff
- Costly as have to hire Quality Control managers
- Lack of EE responsibility
Quality Assurance
Establishing quality control benchmarks throughout production to meet customer expectations.
Standards for:
Design, input quality, production, delivery, and after-sales service
Advantages over Quality Control
- All EEs are responsible
- Increased EE motivation - job enrichment
- Can identify where the problem is
- Prevention rather than inspection - reduced need for final inspection
Benchmarking
A process where you identify the best firms in the industry
Quality Circle
- Groups of EEs meet regularly to discuss ways of improving quality
- Present ideas to management
Total Quality Management (TQM)
- All EEs are involved in the process and it is part of the job
- Think of your Internal Customer
- ‘Customers’ within the organization who use your ‘product’
- Technology is allowing this to go further
International Standards
International Organization for Standardization (ISO)
Pros:
Sign of quality assurance
Cons:
Costly, Training, Bureaucracy involved
