Chap 1: Lean Management

Question 1

What is the based approach ?

Answer 1

• eliminating waste and non-value added activities
• give to the customer exactly what they require
• most efficient way (cost, time and quality)

Question 2

Why lean ?

Answer 2

• can be achieved quickly with dramatic results
• provides common sens approach
• focus on the customer

Question 3

Who created the JIT and lean manufacturing ?

Answer 3

Eli Whitney in the 1890’s

Question 4

What Taylor did ?

Answer 4

He began to look individual workers and work method. The result was time study and standardized work.

Question 5

What is the Ford model ?

Answer 5

He took all the element of manufacturing system and put them in continuous system for manufacturing (Model T)

Question 6

What is the TPS (Toyota Production System) ?

Answer 6

a system centered around JIT and eliminate waste

Question 7

How TPS is maintain ?

Answer 7

through standardized work but with strong respect for people, building trust around teamwork.

Question 8

JIT (Heijunka) definition ?

Answer 8

Build and transport what is needed, at the right quantity and lead time.

Question 9

What autonomation (Jidoka) is ?

Answer 9

stop the process when an error occur

Question 10

What are the 5 biggest principles of Lean managagement ?

Answer 10

1 ) Specify Value

2) Identify the value stream
3) Create flow
4) Create pull
5) Attain perfection

Question 11

Define every principles…

Answer 11

Specify Value 1) Value can be defined by the customer
Identify the value stream
2) A value stream can be defined as the sum of all the
actions required to bring a product /service
Create flow 3) Rethink work-flow to eliminate work in progress,
rework & waiting
Create pull 4) The objective of pull is to minimize overproduction: wasted time, material & service
Attain perfection 5) Perfection no longer becomes unattainable, but which to analyse & drive out waste.

Question 12

Define “Value Added Activity”,”Essential non-value added Activity” and “non-value Activity”…

Answer 12

Value added activity = something the client is willing to pay for
Essential non-value added activity
= something that is currently required by the system but creates
no value
Non-value added activity (WASTE)
= something that creates no value for the client


Question 13

The 7 wastes ?

Answer 13

Transport
Inventory
Motion
Waiting
Over processing
Over production
Defaults
Skills

Question 14

What is PDCA ?

Answer 14

Plan
Do
Check
Act

Question 15

SECAR ?

Answer 15

Simplify
Eliminate
Comnine
Automate
Relocate

Question 16

What is the Kaisen process ?

Answer 16

1) Identify the problem
2) Identify participants –> 100% availability
3) Historical performance data
4) Select suitable location to hold the event –> immediate acess to the “Gemba”
5) Brief the host location to ensure the KIP’s