LEAN Flashcards
Applies Lean to Time to Market process
Lean Development
Lean metric based on the six big losses
OEE
comparable to Formula 1 pit stop
SMED
often organized in U-shaped layouts
Cellular Manufacturing
allows close to zero defects
Six Sigma
continuous improvement
Kaizen
similar to scoreboards in sports
Visual Management
also called supermarket principle
JIT-Production
focuses on equipment related downtime
TPM
lighters function based on this quality method
Poka-Yoke
helps to achieve true Just-in-Time production
One-Piece Flow
value & non-value adding times are key metics
Value Stream Mapping
standardization is a key element
5S
Problem-Solving Tool
A3
Which LEAN tool acts as a KPI for quality?
Six Sigma
Which LEAN tool acts as a KPI for time?
PCE
Which LEAN tool is typically used in maintenance?
TPM
Which LEAN tool is typically used in logistics?
Kanban
Which LEAN tool is typically used in quality?
Poka-Yoke
Which LEAN tool is typically used in production?
SMED
What is considered perfect, world class, and typical performance in OEE?
100%, above 85%, above 60%
Six Sigma allows how many defects/errors per million opportunities?
3.4
JIT allows how many pieces per flow?
1
lean metric based on the six big losses
OEE (Overall Equipment Effectiveness)
What are the three goals of TPM?
- Zero Accidents
- Zero Defects
- Zero Breakdowns
What are the 5 parts to TPM?
- Improvement Maintenance
- Preventative Maintenance
- Maintenance Prevention
- 5S
- Predictive Maintenance
Car example for maintenance prevention
buy a new, reliable car from a manufacturer with excellent quality ratings (e.g. J.D. Power)
Car example for preventative maintenance
clean, wash and wax your car; get routine service/inspections done as suggested by the manufacturer
Car example for improvement maintenance
get occurred damages fixed immediately by the dealership or reputable repair shop
Car example for 5S
familiarize yourself with your car and be able to identify any obvious issues (e.g. strange sounds); perform routine inspection tasks yourself
(e.g. check tire pressure, fluids)
Car example for predictive maintenance
based on driven miles and wear, anticipate future needed improvements/repairs (e.g. brakes, tire replacement) and decide when replacement of car is more economical
What’s the best method to display targets and statuses?
Using a visual scoreboard
What’s the best way to help identify issues in production for downtime issues, material control, etc.?
Visual aids and panels
What’s the main advantage of continuous improvement?
Some innovation leaps, but more continuous improvement - always getting better
What are the 5S’s
Sort, set in order, shine, standardize, sustain
Which Lean tool typically uses Kanban?
JIT production
At a very basic level, SMED deals with what?
Reducing changeover time
