Chapter 16 Flashcards
supply the customer with exactly what the customer wants when the customer wants it, without waste, through continuous improvement.
lean operations
focuses on continuous forced problem solving.
just-in-time (JIT)
emphasizes continuous improvement, respect for people, and standard work practices
Toyota Production System (TPS)
three fundamental issues with lean operations:
eliminate waste, remove variability, and improve throughout
___ is anything that does not add value from the customer point of view
waste
Ohno's Seven Wastes: -overproduction \_\_\_\_\_ \_\_\_\_\_\_ -inventory -motion -overprocessing \_\_\_ \_\_\_\_\_
queues, transportation, defective products
The 5S's: -sort/segregate -simplify/straighten -shine/sweep \_\_\_\_\_ \_\_\_/\_\_\_\_\_\_
standardize, sustain/self-discipline
two additional S’s:
safety and support/maintenance
any deviation from the optimum process
variability
lean systems require managers to reduce variability caused by
internal and external factors
Sources of variability:
- poor processes resulting improper quantities, late, or non-conforming units
- inadequate maintenance
- unknown and changing customer demands
- ___ or ___ drawings, specifications or bills of material.
incomplete or inaccurate
time between arrival of raw materials and the shipping of the finished order
manufacturing cycle time
increases throughput
pull system
exists when a supplier and purchaser work together to remove waste and drive down costs
supplier partnership
four goals of supplier partnerships are:
- removal of unnecessary ___
- removal of ____ _____
- removal of in-transit inventory
- improved quality and ____
activities, in-plant inventory, reliability
___ ____ reduces waste due to movement.
lean layout
large lots and long production lines with single purpose machinery are being replaced by smaller flexible cells. often u-shaped for shorter paths and improved communication. often using group technology concepts
distance reduction
cells designed to be rearranged as volume or designs change. applicable in office environments as well as production settings. facilitates both product and process improvement.
increased flexibility
inventory is at the minimum level necessary to keep operations running.
lean inventory
reducing inventory uncovers the ___ and problems are exposed.
“rocks”
Shingo says “________”
inventory is evil
ideal situation is to have lot sizes of one pulled from one process to the next. often not feasible.
reduce lot sizes
schedules must be communicated inside and outside the organization.
lean scheduling
process frequent small batches, may depend upon market demand.
level schedules
