Lean Foundations Flashcards
What are the four goals of Lean?
1) Eliminate waste
2) Reduce costs
3) Improve quality
4) Increase speed and response times
1.1 What is lean?
To be effective, lean depends heavily on every aspect of company operations __________
working together as one system.
1.1 What is lean?
A strong lean strategy focuses on a firm’s ________ and _______.
competitors
customers
1.2 Why use lean?
For kaizen to be effective, it’s important that employees feel _______.
empowered to make changes
1.3 The need for continuous improvement
What is kaizen?
small incremental improvements made continuously over the long term
1.3 The need for continuous improvement
A kaizen blitz is a _______ executed very ______, and is dedicated to ________ or ________ immediately.
project, quickly, solving a problem, fixing a process
1.3 The need for continuous improvement
__________ is a good place to start when implementing a continuous improvement culture.
Reviewing standard business processes
A process map identifies the __________ activities in a process.
sequence of
2.1 Process mapping
What are the 2 basic components of a process?
1) Tasks
2) Activities
2.1 Process mapping
What are tasks (process mapping)?
Specific jobs that, when sequenced correctly, create the final output of a process
2.1 Process mapping
What are activities (process mapping)?
A group of tasks that create some intermediate output
2.1 Process mapping
What are the 5 basic process mapping symbols?
⬯ - start and end point ▭ - specific task or activity △ - wait time ◇ - decision point ➪ - direction of flow
2.1 Process mapping
When creating process maps, start with a ______ map, then fill in ________ as required.
large scale, details
2.1 Process mapping
What are the 5 steps of the Lean Improvement Cycle?
1) Define value
2) Map the value stream
3) Create flow
4) Establish pull where possible
5) Seek perfection
2.2 Value stream analysis
What is Business Process Re-Engineering?
Rethinking and redesigning processes to better serve customer needs.
2.3 Process re-engineering
What are the 4 steps of Process Re-Engineering?
1) Describe the process (what product/service do you)
2) Determine the output of the process
3) Determine costs
4) Consider how to re-engineer the process
2.3 Process re-engineering
What is the Principle of Ideality?
The most ideal solution is the one that doesn’t exist…at the moment
2.4 Principle of Ideality
What is an Elegant Solution?
A solution in which the optimal outcome is reached with the least amount of effort
2.5 The elegant solution
Toyota’s approach to elegance and innovation follows which 3 principles?
1) Ingenuity in craft
2) Pursuit of perfection
3) Rhythm of fit
2.5 The elegant solution
What are Michael L. George’s 3 rules for complexity?
1) Eliminate complexity customers won’t pay for
2) Exploit the complexity customers will pay for
3) Minimize costs of the complexity you offer
2.6 The cost of complexity
What is throughput at the company level?
the rate at which you are generating cash through selling your products
2.7 Theory of constraints
What is throughput at the factory level?
the rate at which you are making your products
2.7 Theory of constraints
What is throughput at the equipment level?
the rate at which an individual machine produces output to help make products
2.7 Theory of constraints
The theory of constraints proposes to __________
maximize factory throughput by efficiently managing bottlenecks.
2.7 Theory of constraints
