Chapter 16 Flashcards
a focus on continuous improvement
kaizen
members of a work cell or team meet to develop improvements in the process
kaizen event
any activity that does not add value in the eyes of the customer
waste
is any deviation from the optimum process that delivers perfect product on time, every time
variability
: the rate at which units move through a production process
Throughput:
___is the war on waste
lean
the japanese word for waste
muda
: producing more than the customer orders or producing early
Overproduction:
: idle time, storage and waiting
Queues:
moving material between plants or between work centers
transportation
unnecessary raw material, WIP, finished goods and excess operating supplies
inventory
: movement of equipment or people that adds no value
motions
work performed on the product that adds no value
overprocessing
returns, warranty claims, rework and scrap
Defective Products:
Lean systems require managers to reduce variability caused by
both internal and external factors
the time between the arrival of raw materials and the shipping of the finished order
A “pull” system increases throughput
Manufacturing cycle time:
produces finished goods inventory in advance of customer demand using a forecast of sales
Push system:
employees at a given operation (work station) go to the source of the required parts, such as machining or subassembly, and withdraw the units as they need them
Pull system:
: the process of producing large quantities of items as a group before being transferred to the next operation
batching
the concept of ideally using batch sizes of one
Single-piece flow
To utilize single-piece flow, a company must be able to ________ quickly and inexpensively by reducing setup times
To utilize single-piece flow, a company must be able to change between products quickly and inexpensively by reducing setup times
the Japanese word for card, which has come to mean “signal”
moves parts through production via a “pull” from a signal
kanban
: indicators for operating activities that are placed in plain sight of all employees so that everyone can quickly and easily understand the status and performance of the work system
visual controls
refers to quick setup or changeover of tooling and fixtures in processes so that multiple products in smaller batches can be run on the same equipment
Single Minute Exchange of Dies (SMED)
activities that can only be done while machine is stopped
Internal:
activities that do not require stopping the machine
external
ensuring that operating systems will perform their intended function reliably
Total Productive Maintenance (TPM):
The 5S principles are as follows:
sort, straighten, shine, standardize, sustain
US Managers often add two additional S’s
safety and support/maintenance
