A3 System Control and Management Flashcards

1
Q

Main concept behind Toyota Production System

A

Eliminate unnecessary resources (waste) > increased production efficiency & effectiveness
Produce required product at right time, quantity & quality (Just-in-time)

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2
Q

Is Just-in-time production pull/push system

A

Pull since each stage initiates production by requesting an order from prev. stage in production process

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3
Q

Just-in-time As

A

Bottlenecks eliminated
Batch sizes reduced
Waiting time of parts reduced
WIP reduced (holding/storage cost reduced)
Setup time reduced

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4
Q

7 wastes

A

0 defects
0 inventories
0 setup times
0 handling
0 breakdowns
0 lead times
batch size of 1

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5
Q

How is JIT production controlled?

A

Kanban card/electronic equivalent authorises manufacture of components once subsequent process complete

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6
Q

How does Kanban identify wastes

A

Build-up of Kanban cards indicates more WIP & location of bottleneck

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7
Q

Quality from customer’s POV

A

Does product meet needs & expectations
Quantitative - how fast/light/good value
Qualitative - attractive, brand loyalty

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8
Q

Quality from manufacturer’s POV

A

Is product made to exact specification
Quantitative - tolerances in geometry, surface finish
Qualitative - visual inspection, perceived build quality

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9
Q

QA

A

quality assurance - iterative system for preventing defects as far as possible
Products should be fit for purpose
Minimise mistakes so products are right 1st time

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10
Q

QC

A

quality control - system for detecting defects in product/process
Used in QA to detect size & frequency of defects

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11
Q

Kaizen

A

system of small & continuous improvement in a process

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12
Q

Why is Kaizen more effective than trad suggestion scheme

A

Why don’t I…
Personal, fast implementation
Low operation cost
No political barriers
Everyone participates, setting own achievable goals
Good teamworking

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13
Q

Six sigma

A

Statistical analysis tool to improve quality by identifying & removing causes of defects
In manufacturing aim to achieve error rate of 3.4 defects per million opportunities (DPMO)

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14
Q

Six Sigma As

A

Quantitative aim to activities designed to improve quality, save time & cut costs by improving process performance & reducing variation

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15
Q

Six Sigma Ds

A

Basic process dressed up in management jargon, no statistical justification for using 6 sigmas. 3.4 DPMO arbitrary & doesn’t necessarily hold for all processes e.g. nuclear reactor rods vs drain cleaning rods

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15
Q

How Taguchi developed trad Goal Post philosophy of achieving quality

A

More resolution within good (poor, fair, good, best) to account for variation in quality above standard required

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15
Q

Tachuchi’s Loss Methods aim

A

minimise loss to society due to poor quality
customers lose money replacing products more often
manufacturers lose rep (lose customers)
Quality loss determined by customer dissatisfaction

16
Q

How does Taguchi suggest a manufacturer can reduce loss?

A

Design products to eliminate potential for variation during production (simply)
Use statistics to investigate parameters that vary uncontrollably in real life (weather)

17
Q

Taguchi Loss Function aim

A

Quantitatively describe loss to society
As quality of part nears its limits, increasing less likely to satisfy customers > more loss

18
Q

Knock-on effects of loss

A

Poor quality products, loss of sales
factories close
loss of jobs
loss of income to spend on products
less tax being paid

19
Q

Why would manufacturer maintain an inventory

A

JIT techniques not perfect
Economies of scale - bulk buying leads to inventory
Time - maintain supply (processes might work perfectly but not customers/suppliers)
Uncertainties - irregular order patterns, unexpected demand - inventories buffer demand

20
Q

Problems maintaining inventory

A

Large amount of WIP & finished stock (handling & storage costs) needed

21
Q

How does MRP address inventory problems?

A

materials requirement planning
Use firm orders for products & future requirements based on sales forecasts to calc. what materials ordered & when

22
Q

Aims of MRP

A

materials requirement planning
Minimise inventory levels
Ensure timely delivery of materials/products
Aid planning of manufacturing & delivery of materials/products

23
Q

2 outputs of MRP

A

materials requirement planning
Recommended Production Schedule
Recommended Purchasing Schedule

24
Q

MRP As

A

materials requirement planning improves production planning & forces companies to be more organised in other aspects e.g. marketing, purchasing

25
Q

MRP Ds

A

materials requirement planning doesn’t account for plant capacity, how many workers needed, cash needed to buy materials

26
Q

MRPII

A

Manufacturing resource planning
Overcomes limitations of MRP by coordinating production resources of manufacturing organisation across factories/sites/countries

27
Q

How does MRPII work?

A

Take MPS (master production schedule), complete rough capacity planning, modify MPS & initiate MRP process

28
Q

What does ERP do?

A

Enterprise resource planning
Extends ideas of MRPII across whole business incl. finance, human resources in addition to manufacturing

29
Q

Why is it difficult to implement ERP?

A

enterprise resource planning
Communication between all parts of a business
Managing fast evolving businesses (e-commerce)
Practicalities of installing hardware & software
Changes to working practices
Training staff in new systems

30
Q

ERP As

A

enterprise resource planning
All business systems integrated & work together
Data flows freely throughout
Minimises chance of losing important info
Better view of business, easier to make decisions
Reduces lead times through better process control i.e. data to support MRP & MRPII
Help manages complex bill-of-materials

31
Q

ERP Ds

A

enterprise resource planning
Expensive & time consuming to implement
Reduce morale (force workers to adapt to new business practices)
Removes ownership of business areas
Restricts existing process that are perceived to ‘work well already’
Problems sharing complex/sensitive data
Forcing compliance to a standard reduces competitiveness

32
Q

Lean manufacturing

A

0 wastes from JIT developed into a broader & wider looking philosophy of lean manufacturing that exists throughout supply chain

33
Q

Leanness

A

Combo of eliminating unnecessary resources (0 wastes) & increasing efficiency & effectiveness (Kaizen)

34
Q

Main areas of manufacturing leanness can be applied to?

A

Plant
Supplier network
Production development
Relationships with distributors & customers

35
Q

Tier1 to 2 supplier to an OEM As

A

original equipment manufacturer
encourages competition
Opportunities to remain as suppliers
opportunities arise from good performance (quality, cost, delivery, engineering capability)

36
Q

Agile manufacturing

A

Next step in development from lean manufacturing > take advantage of leanness to be an adaptable, rapidly responding (right product, right time) business

37
Q

Global manufacturing

A

Use philosophies of leanness & agile manufacturing to take advantage of globalisation (e.g. production located where cost/expertise exists, take advantage of local knowledge for product development/marketing)

38
Q

E-manufacturing

A

Take advantage of modern IT systems (cloud computing etc.) to breakdown geographic barriers to the business