Basics Chapter 1-3 Flashcards
Taylor: Scientific Management - Explanation & Approach
Management, work and companies should only be optimized by scientific approaches to solve social problem and maximize the prosperity both of the employer and the employee.
Approach
Establishment of a “work bureau”
which prepares the work for the shop
floor in detail
IPS - Definition
Logically structuring the methodical standards within the production. A production system fixes how to produce.
IPS - Characteristics
- Structuring in fields of activities
- Description of methods as standards
- Realisation of a lean factory regarding the four goal dimensions variability, quality, speed and profitability
- Measures the continuous improvement of processes with appropriate figures
- High joint responsibility of employees
IPS - 6 Goals
- Lowest Costs
- Highest Quality
- Shortest Lead Times
- Highest Security
- High Working morale
- Changeability
Waste - “3 Mu”
- Muda: Waste
- Muri: Overburden
- Mura: Inconsistency
7 forms of waste (muda)
- Over-production
- Waiting Time
- Transportation
- Inappropriate Processing
- Unnecessary Inventory
- Unnecessary Motion
- Defects
Gemba
Place where the value added activities take place => mainly shopfloor => Gemba walks
Kaizen / CIP - 3 Principles
- Employees should be given responsibility over their tasks and they describe problems or make suggestions for improvements
- Systematical infrastructure to conduct suggestions for implementation
- Suggestions of employees will influence management decisions
Kaizen / CIP - Goals
- Simple, fast and cost effective resolving of problems
- Permanent consideration of customer’s benefit and value
- Avoidance of waste (muda), overload (muri) and inconsistency (mura)
Kaikaku =/= Kaizen - Kaikaku Characteristics
Kaikaku: Radical change/redesign, innovation
• strategic level
• one large scope event
• Planning timeline of weeks and months
• Slower Implementation but large effect on value stream
• High requirement of labour and capital
Kaizen + Kaikaku
Kaizen: small steps to improve ops to overcome small barriers
Kaikaku: remove large obstacles to reach strategic goals
=> Appropriate combination can induce achievement of higher goals in shorter time
Value Stream Mapping (VSM) - Definition
Technique by which the flow of materials and information can be analysed along the production process, including suppliers and customers.
The VS describes the production flow of a product from raw material ( to the hands of the customer.
Value Stream Mapping (VSM) - Characteristics
- Change of Perspective: makes view free for the flow
- Creates common understanding of target and current status
- Helps to identify causes of waste
- Reveals divergence of value-adding and non-value-adding times
- Highlights levers for the optimisation of the production
Value Stream Mapping (VSM) - 4 Stages
- Product family selection
- Mapping of current state
- developing and mapping of future state
- step by step implementation
5S
- Sorting: Only essential items in easy accessibly locations
- Stabilisation: Place for everything and everything in its place
- Systematic Cleaning: Clean workplace & equipment and keep clean
- Standardisation: Practices should be consistent and standardised
- Self discipline: Maintain and review standards
