Lean Foundations Flashcards
What are Frederick Winslow Taylor’s contributions to lean principles?
Taylor was the first efficiency expert. He applied the scientific method to time and motion studies to achieve the maximum output. He accomplished this by having management in control of the workplace and by detailing the minute routine of the worker. Through operational analysis, he took away job complexity and simplified operations.
What are key concepts Taylor developed to drive efficiency?
Key concepts Taylor developed include: 1) understand each element of a task, 2) select, train and develop the worker, 3) have a division of work between management and workers, and 4) cooperate with the worker to follow procedures.
How did Henry Ford become the “father of mass production?”
The successful implementation of the assembly line at his Highland Park Plant in Detroit, Michigan, in 1913 reduced costs and increased productivity for the Ford Motor Company. Reduced manufacturing costs made cars more affordable for Americans.
How did Ford’s assembly line implementation impact worker task time?
In 1908, workers required an average station task time of 514 minutes. Through improvement work and time studies, the average time was reduced to 2.3 minutes. The introduction of the assembly line pushed the average task time down to 1.19 minutes.
How did Ford’s assembly line impact labor turnover and wages?
Use the the assembly line resulted in a labor turnover rate of 380% in the beginning of 1913 and 900% by year end. On January 4, 1914, wages were increased to $5.00 per day. The increased wages resulted in a much improved retention rate.
What benefits did companies like Ford Motor Company gain from mass production techniques?
Mass production techniques involved the interchangeability of parts and workers, simpler tasks and better organization.
What is the concept of jidoka developed by Sakichi Toyoda?
Jidoka refers to automation with a human touch. Applied to the power loom invented by Toyoda, this invention was designed to stop the loom whenever a thread broke. A human did not need to be present to oversee each loom. This enabled workers to handle more than one loom and provide more value-added work.
What contributions did Kiichiro Toyoda make to lean principles?
Kiichiro Toyoda continued the work of his father Sakichi Toyoda, promoted the use of mistake-proofing concepts and just-in-time production techniques, and became the second president of the Toyota Motor Company.
What are the Toyota Production System techniques used by Taiichi Ohno to eliminate waste within Toyota and its suppliers?
Ohno developed the following techniques: 1) a pull system, 2) muda (the seven types of waste, 3) quick die changes, 4) flexible job assignments, 5) removing non-value added work, 6) kanban methods, 7) u-shaped cells, 8) one-piece flows and 9) production leveling.
