Keeping ahead of the game: Improvement Flashcards
Improvement in OM
Improvement means; - Not being content with the status quo of operation - Looking ahead to the future - Getting ahead of competition Approaches to improvement - TQM - Lean - Business process re-engineering - Six Sigma
Total Quality Management
- Puts quality at the heart of ops
- Customer focused, improvement involves everyone
Lean
- Waste reduction
- General work culture of continuous improvement
Business process re-engineering
- Removal of non-value adding processes
- Radical changes as opposed to incremental ones
The Lean Philosophy
- Toyota Production System TPS
- Lean means minimising waste
- Produce the right amount, at the right time, in the right volumes at the minimal cost
5 Broad principles to lean
- Value in a production system should be defined by the customers point of view
- Each step should be evaluated in terms of value contribution
- The value stream should be sequenced and integrated in the smoothest way towards the customer
- Production should be pulled from customer demand
- All members should get involved with lean to promote continuous improvement
Waste Reduction
- Anything that doesn’t add value to the process
- Muda - activities that don’t add value
- Mura - waste associated with unevenness of processes
- Muri - waste resulting from overburden of people and processes
- Forms of Waste
- Overproduction
- Waiting time
- Transport
- Process
- Inventory
- Motion
- Defectiveness
Just In Time
- Perfect quality, exact quantities, exactly timed, exactly where required
- Best way of reducing Mura
- JIT operates a pull control
- JIT tries to match supply and demand as best as possible; providing goods and services exactly when they are needed
- Pull control is usually enabled by KANBAN;
Controls the transfer of items between stages of the operation
A Kanban coming from downstream triggers the need for delivery
Kanban system are enablers of JIT
Eliminating waste through stream-lined flow
What is the best possible shape for your process flow
- Can workers communicate and help each other?
- U-shapes are very popular
Value Stream Mapping is a tool for understanding how value is added to a product/service as it moves through the process
Ensure high visibility in the process
- Signage
- Lights
- Visual control systems
Human error can lead to mistakes
Poke Yoke tries to reduce human error
Eliminating waste through flexible process
Goes hand-in-hand with JIT and stream lined flow
- Resources need to be able to change output timing and volume without incurring long delays
- Use smaller batch sizes; reduces average inventory, lesser risk when considering detection of quality issues, uniform workload on the system, however means more set ups
Use a shorter set up
- Given that the number of set ups will increase we need to reduce the time it takes
Classic Machinery Changeover
- Manufacturing using batch will often have some tools for making different products
- Between every batch thats made, machines need to be changed over
- Changeover is a non-value-adding activity and therefore waste
Single Minute Exchange of Die (SMED)
SMED means that minutes should be a single digit Shorter change over times means; - freeing up machines - Reducing set up costs - Smaller cycle inventory - Make JIT possible
Step 1. Measure an analyse change over activities
- Divide external and internal activities
- Convert internal and external activities
- Continually improve both
Eliminating waste through minimising variability
-Variability in the quality of products and services in the system
- Variability in the mix of products and services moving through the system
- Variability in transportation processes in the system
Total productive Maintenance TPM
- Eliminates the variability in operations caused by the effect of breakdowns
- Planned maintenance is much preferable than unplanned
Total Productive Maintenance TPM
- Company wide policy whose specific aim is the maintenance, quality and efficiency of equipment
- TPM core component of the lean philosophy and states that if equipment is maintained well it will be more reliable and efficient
- Uses metric called Overall Operational Effectiveness
Six Sigma
Quality Improvement
- Zero defects objectives
- Narrow down design specifications and minimise product variability
