Lean

Question 1

5 value added work (customer cares)

Answer 1

1. tear down
2. prepping panels for paint
3. applying filler
4. paint
5. installing parts and replacing fluids

Question 2

8 non value added work (customer does not care)

Answer 2

1. searching for tools
2. setting up paint booth
3. traveling to and from office
4. waiting for parts
5. transporting cars around shop
6. mistakes during repairs
7. comebacks
8. too much sanding/buffing time (extra processing)

Question 3

what are the 8 wastes in auto body repair

Answer 3

1. over production
2. extra processing
3. transportation
4. motion
5. waiting
6. defects or rejects
7. inventory
8. non utilized talents

Question 4

what is overproduction?

Answer 4

doing more than required, or before it is needed. techs working before parts are available, processing big jobs before fast tracks, processing estimates in wrong order

Question 5

what is extra processing?

Answer 5

redundancy, extra effort, inability to identify when the work is done.

Question 6

what is transportation in lean?

Answer 6

moving parts, products, materials around the shop. eats up time. poorly planned parking/flow. moving cars to unblock other cars.

Question 7

what is motion in lean?

Answer 7

tech moving without productivity. Any time a tech stops working in order to locate something they need, or someone, reviewing information a second time, walking away from work are to solve a problem… is wasted action. without an organized shop, waste multiplies.

Question 8

what is waiting in Lean?

Answer 8

when any process is out of balance and causes people and machines to stop and wait.

Question 9

what are defects in lean?

Answer 9

rework, mistakes, quality errors and comebacks

Question 10

what is inventory in lean?

Answer 10

excessive shop supplies parts, and material occupy floor space.

Question 11

three types of inventory in lean?

Answer 11

1. raw material or parts
2. work in process
3. finished goods

Question 12

what is the cornerstone of lean?

Answer 12

waste removal

Question 13

what is non utilized talents

Answer 13

cross train employees to be able to help other departments or you will have non utilized talets

Question 14

high priority waste

Answer 14

tech leaving work area

techs searching for tools, parts, supervisors, supplies or any reason leaving area.

Question 15

medium priority waste

Answer 15

tech removing parts from packaging (should be removed in parts room)
lack of timely information causing wait times

Question 16

low priority waste

Answer 16

looking for tools in work area.

Question 17

goal of lean?

Answer 17

reduce waste and maximize time spent on performing work customers want you to do.

Question 18

what are the 6 auto body metrics in Lean?

Answer 18

1. productivity
2. quality
3. inventory/wip
4. floor space use
5. throughput time
6. productivity

Question 19

what is productivity in lean?

Answer 19

working at a pace that is sustainable, safe and keeps the flow. focusing on the efficiency of tech is critical because they are value added, their product pays the company’s bills.
less personnel equates to less labor, less tools, less workstations less material.