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
Japanese word for card. authorization for the next container of material to be produced. many different sorts of signals are used but system is still called this
Kanban
lean exposes poor ___
quality
because lead times are shorter, quality problems are ___ ____. better quality means fewer buffers and allows simpler lean systems to be used.
exposed sooner.
TPS uses continuous improvement, builds an organizational culture and value system that stresses improvement of all processes called
kaizen
TPS word for stopping production because of a defect
jidoka
lean ___ understands the customer and their expectations.
organizations
lean systems tend to have the following attributes:
- respect and develop employees
- empower employees
- develop worker flexibility
- develop collaborative partnerships with suppliers
- eliminate waste
yay
maximize resource use and economic efficiency. focus on issues outside the immediate firm. driving out waste is the common ground
lean sustainibility
Lean techniques used in manufacturing are used in services. these are: acronoym for it is SLIS
suppliers, layouts, inventory and scheduling.
