Chapter 16: Lean Operations

Question 1

JIT

Answer 1

internal focus
make what is needed when it is needed
excellent vehicle for finding and eliminating problems

Question 2

Ohno’s Seven Wastes

Answer 2

Overproduction
Over processing
Defective products
Queues
Motion
Transportation

Question 3

5S’s

Answer 3

Shine / Sweep
Sustain / Self discipline
Simplify / Straighten
Sort / Segregate
Standardize

Question 4

Pull system

Answer 4

a concept that results in material being produced only when requested and moved to where it is needed just as it is​ needed

Question 5

Lean Quality Tactic

Answer 5

empower employees
build​ fail-safe methods
use statistical process control

Question 6

Consignment inventory

Answer 6

the supplier maintains title to the inventory until it is​ used

Question 7

Lean Inventory Tactic

Answer 7

reduce lot size
reduce setup time
use group technology

Question 8

Toyota Production System - Standard of work practice

Answer 8

Internal and external​ customer-supplier connections are​ direct, specifying​ personnel, methods,​ timing, and quantity.
Material and service flows are to be simple and direct.
Work is completely specified as to​ content, sequence,​ timing, and outcome.
Improvements in the system must be made in accordance with the​ “scientific method,” at the lowest possible level in the organization

Question 9

jidoka

Answer 9

stop production when a defect occurs

Question 10

Toyotas New Plant features

Answer 10

The assembly line has cars sitting​ side-by-side, rather than​ bumper-to-bumper.
The assembly line uses quiet friction rollers with fewer moving​ parts, requiring less maintenance than conventional lines and reducing worker fatigue.
Retooling permits faster​ changeovers, allowing for shorter product runs of​ components, supporting level scheduling.

Question 11

Lean sustainability

Answer 11

Lean and sustainability both seek to maximize resource and economic efficiency.

Sustainability requires examining the systems in which the firm and its stakeholders operate.

Sustainability drives out waste because waste has adverse affects on the​ environment, while lean drives out waste because waste adds nothing for the customer

Question 12

Lean Operations

Answer 12

Develop collaborative partnerships with suppliers.
Develop worker flexibility
Empower employees.