Chpt 16 Flashcards
What is Muda/ muri/ mura?
Muda: Waste or anything other than which adds value to the product or service
Muri: Overburdened
Mura: unevenness, fluctuation, variation
What are the 8 Wastes? TIMWOODS
Transportation (unnecessary), Inventory (excess raw materials, WIP or finished goods), Motion, Waiting, Overproduction (producing more than what is needed), Overprocessing (unnecessary steps), Defects, and (under-utilized) skills
What are the 8 Wastes? TIMWOODS
Transportation (unnecessary), Inventory (excess raw materials, WIP or finished goods), Motion, Waiting, Overproduction (producing more than what is needed), Overprocessing (unnecessary steps), Defects, and (under-utilized) skills
What is lean production?
A philosophy and a collection of management methods and techniques aimed at eliminating waste and continuously improving manufacturing operations.
What are the 10 basic elements of lean production?
The 10 basic elements are:
1. Flexible resources,
2. Cellular layouts,
3. Pull system,
4. Kanbans,
5. Small lots, (inventory hides problems)
6. Quick setups, INTERNAL (when process is stopped) or EXTERNAL (in advance) (set up time is the biggest bottleneck)
7. Uniform production levels,
8. Quality at the source,
9. Total productive maintenance (Breakdown and Preventative),
10. Supplier networks.
How do lean production practices differ between North American and Japan-based facilities?
North American plants are larger, have less frequent deliveries, hold more buffer inventory, and use simpler kanbans compared to Japan-based plants.
What is a kaizen blitz?
A kaizen blitz is an intense process improvement activity conducted over a week’s time that aims for immediate results.
What are some benefits of lean production?
Benefits include reductions in manufacturing cycle time, inventory, labor costs, and space requirements.
What are some drawbacks of lean production?
Drawbacks include difficulties in maintaining discipline, challenges with unexpected changes in demand or supply, and it may not suit high-volume repetitive items.
In what other situations can lean systems be applied?
Lean systems can be applied in fast-food restaurants, construction firms, companies streamlining operations, lens providers, and retailers introducing new clothing lines.
What are andons?
Call lights that signal quality problems. (can be in different colors)
What is breakdown maintenance?
Repairs needed to make a failed machine operational.
What is external setup?
Setup activities that can be performed in advance.
What is the 5 Whys technique?
Repeatedly asking ‘why?’ until a root cause is identified.
What are general-purpose machines?
Machines that perform several basic functions.
What is internal setup?
Setup activities that can be performed only when a process is stopped.
What is jidoka?
Authority to stop the production line.
What is just-in-time (JIT)?
A system that smooths the flow of material to arrive just as it is needed; evolved into a system for eliminating waste.
What is kaizen?
A system of continuous improvement; ‘KAI:change for the ZEN:good of all.’
What is kanban?
A card that corresponds to a standard quantity of production (usually a container size).
What is a kanban square?
A marked area designated to hold items.
What is lean production?
An integrated management system that emphasizes the elimination of waste and the continuous improvement of operations.
What is lean Six Sigma?
A combination of lean production’s principles for eliminating waste with Six Sigma’s reduction of variability.
What are manufacturing cells?
Dissimilar machines brought together to manufacture a family of parts.
What is material kanban?
A rectangular kanban used to order material in advance of a process.
What is muda?
Waste, or anything other than that which adds value to the product or service.
What are multifunctional workers?
Workers who perform more than one job.
What is poka-yoke?
A foolproof device that prevents defects from occurring.
What is preventive maintenance?
A system of periodic inspection and maintenance designed to keep a machine in operation.
What is production kanban?
Maintains discipline of pull production & authorizes production and movement of goods
What is a pull system?
A production system that relies on customer requests.
What is a push system?
A production system that relies on a predetermined schedule.
What is a signal kanban?
A triangular kanban used to signal production at the previous workstation.
What is a supplier kanban?
A kanban that rotates between the factory and suppliers.
What is takt time?
The pace at which production should take place to match customer demand.
What is total productive maintenance (TPM)?
A system that combines the practice of preventive maintenance with the concepts of total quality.
What is undercapacity?
Scheduling extra time built into a schedule for planning, problem solving, and maintenance.
What are uniform production levels?
The result of smoothing production requirements on the final assembly line.
What are visual control procedures?
Procedures or mechanisms that make problems visible.
What is a withdrawal kanban?
A card authorizing the movement of goods.
What is SMED (single-minute exchange of dies)?
Seperate internal & external setups, convert internal setups to external setups, streamline set up aspects, perform setup activities in parallel or eliminate them entirely
Why define supplier networks?
long-term, synchronized w/production, supplier certification, mixed load/frequent deliveries, precise delivery, standardized, locatio
Name some pros of lean production:
- reduced inventory
- Improved quality
- Lower costs
- Reduce space requirements
-Shorter lead time - Increase productivity
- Greater flexibility
- Better relationship w/suppliers
- Simplified scheduling & control activities
- Increased capacity
- Better use of human resources
- More product variety
Name some cons of lean production:
- Highly variable demand
- Large variety of low-volume products
- Custom engineered products
- Mass production parts
- Unexpected changes in demand or supply
- Level of innate risk
