5.3 Lean Production HL Flashcards
Lean production
producing efficiently and minimizing wasted resources whilst maintaining high quality
examples of wastes
- transportation costs
- movement of people
- holding too much stock
- waiting time in production
- too much complexity (overprocessing)
- defect products
- overproduction
how 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 EE’s contribute to improving the production process
opposite of autocratic leadership
large one-off imrpovements by management
requirements for kaizen and pros and cons
requirements:
* inclusive culture
* all EEs are empowered
P:
* motivation for EEs
* new ideas
C:
* resistance from senior managers
* training needed
Just in time production
a stock control method in which inputs arrive just before they are used in the production process
finish products are delivered to consumers as soon as they are produced
requirements for JIT
- good relationship w suppliers
- flexible staff and machinery
- accurate forecasted demand (sales)
- suitable IT systems
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- stock does not become outdated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
recycling
resource recovery model
quality control
inspection of the product or service
impact:
* negativity amongst staff
* costly as have to hire quality control managers
* lack of EE responsibility
quality assurance
setting agreed quality standards at all stages in the production process to ensure customer satisfaction
not just on the finished product
standards for:
design, input quality, production, delivery and after-sales service
advantages of quality assurance over 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 and compare this to your own firm
quality circle
group of EEs meet regularly to discuss ways of improving quality
they then present their ideas to management
Total quality management (TQM)
All EEs are involved in the process and it is part of the job
requires a company culture and extensive training
think of your internal customer - ‘customers’ wihtin the organisation who use your ‘product’
technology is allowing this to go further
international standards
international organisation for standardization (ISO)
sign of quality assurance but:
costly
training
bureaucracy involved
