A3 System Control and Management Flashcards
Main concept behind Toyota Production System
Eliminate unnecessary resources (waste) > increased production efficiency & effectiveness
Produce required product at right time, quantity & quality (Just-in-time)
Is Just-in-time production pull/push system
Pull since each stage initiates production by requesting an order from prev. stage in production process
Just-in-time As
Bottlenecks eliminated
Batch sizes reduced
Waiting time of parts reduced
WIP reduced (holding/storage cost reduced)
Setup time reduced
7 wastes
0 defects
0 inventories
0 setup times
0 handling
0 breakdowns
0 lead times
batch size of 1
How is JIT production controlled?
Kanban card/electronic equivalent authorises manufacture of components once subsequent process complete
How does Kanban identify wastes
Build-up of Kanban cards indicates more WIP & location of bottleneck
Quality from customer’s POV
Does product meet needs & expectations
Quantitative - how fast/light/good value
Qualitative - attractive, brand loyalty
Quality from manufacturer’s POV
Is product made to exact specification
Quantitative - tolerances in geometry, surface finish
Qualitative - visual inspection, perceived build quality
QA
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
QC
quality control - system for detecting defects in product/process
Used in QA to detect size & frequency of defects
Kaizen
system of small & continuous improvement in a process
Why is Kaizen more effective than trad suggestion scheme
Why don’t I…
Personal, fast implementation
Low operation cost
No political barriers
Everyone participates, setting own achievable goals
Good teamworking
Six sigma
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)
Six Sigma As
Quantitative aim to activities designed to improve quality, save time & cut costs by improving process performance & reducing variation
Six Sigma Ds
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
How Taguchi developed trad Goal Post philosophy of achieving quality
More resolution within good (poor, fair, good, best) to account for variation in quality above standard required