Lean For Collision Workbook Jason

Question 1

Five critical success factors for lean

Answer 1

1. Process, quality, speed, and cost
2. find keep and develop the best and the brightest
3. leader ship skills and ability to lead change
4. culture of continuous improvement
5. measured performance, market driven

Question 2

7 wastes

Answer 2

1. Overproduction
2. Inventory
3. Time waiting (parts or decisions)
4. Defects
5. Wasted motion
6. Transportation
7. Over processing

Question 3

How to correct for waste in lean

Answer 3

Define where waste is make it tangible. Focus on small opportunities
Continuous improvement, never done

Question 4

What is littles law

Answer 4

AKA law of the funnel.
MIT professor John Little calculates cycle time:

Average number of cars delivered per day
     (Total vehicles delivered last month divided by # of working days in month) 
Divided by 
# of cars in shop: WIP
Equals cycle time.

2 cars delivered per day/20 cars in WIP= 10 cycle time days.

Question 5

To reduce your cycle time, you often need to reduce WIP or temporarily increase production hours or solve problems that cause cars to wait.

How to choose an optimum WIP number for your shop:

Answer 5

Average repairs delivered daily
(Delivered last month divided by working days)

Cycle time goal

Multiply repairs delivered daily by goal cycle time days = optimum WIP units.

Four deliveries a day/ 7 goal cycle time days= 28 units in WIP

Question 6

Cycle time is calculated

Answer 6

WIP

/ daily output (deliveries per day)

Question 7

How to get TT or average billed hours per day

Answer 7

Average RO hours divided by avg cycle time

Question 8

Calculate avg hours billed per day TT for this:

17 hours avg RO

10 days avg cycle time

Is how many hours per day TT?

Answer 8

1.7 hours/day TT

Question 9

9 Problems to solve to operate with lower WIP at a faster cycle time:

Answer 9

Estimate inaccuracy
Wrong parts
Missing parts
Hidden damage
Rework WDO
Quality
Expediting Fast tracks
Scheduling 
Waiting for tech