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
The goal of the theory of constraints is to manage bottlenecks to maximize ________ in spite of _______.
throughput, limitations
2.7 Theory of constraints
The theory of constraints eliminates __________ by managing ________ through the bottleneck.
excess inventory, flow
2.7 Theory of constraints
The elegant solution applies the _____ , with the least amount of _____ , in _____ steps.
simplest approach, effort, small continuous improvement
Chapter 2 quiz
The key to successfully managing materials is ______.
flow
3.2 Demand-driven materials
What is the 3 step procedure developed by Carol Ptak and Chad Smith for demand driven material flow?
1) Position inventory at strategic locations
2) Protect inventory positions with buffer inventory
3) Pull order or purchases
3.2 Demand driven materials
Which 2 important decisions must lean managers make about inventory?
1) When to produce?
2) How much to produce?
” To produce just enough just in time, you must balance the cost of holding inventory with the cost of not having products when your customers want them.”
3.3 Lean Inventory
Which 3 key measures of inventory do managers use to balance cost of holding inventory vs. cost of not having enough product?
1) The total # of units in inventory
2) The total $ value of inventory
3) How fast you turn your inventory
3.3 Lean Inventory
A pull system is designed to ______.
limit inventory to the lowest level possible while maintaining customer requirements
3.4 The pull approach
What is a kanban system?
a production control system that uses visual signals to control what is produced and when
3.4 The pull approach
What are the 5s’s?
1) Sort
2) Set
3) Shine
4) Standardize
5) Sustain
3.6 Lean work stations
In order for 5S to be effective, employees must be ______.
empowered to be responsible for their work environment.
3.6 Lean work stations
What is the goal of total productive maintenance?
zero unplanned equipment downtime
3.7 TPM
Overall Equipment Maintenance (OEE) allows you to measure the amount of planned manufacturing time that is _________
actually productive
3.7 TPM
Calculating OEE:
Availability
% of planned production time that the machine is ready
3.7 TPM
Calculating OEE:
Performance
compares actual output to the maximum output possible. Expressed as a %
3.7 TPM
Calculating OEE:
Quality
measures defects. 100% quality means zero rejects or scrapped parts.
3.7 TPM
What is jidoka?
automation with a human touch (Toyota)
3.8 Lean quality
Lean delivery requires finding the correct balance between ______ delivery and the _______ delivery.
on-time, cost of providing the on-time
4.1 Lean delivery
What is often the first and final step of managing a supply chain?
transportation
4.2 Lean transportation
What is a supply chain?
The network of suppliers, manufacturers and distributors that make products available to customers
4.2 Lean transportation
What is leagility?
a hybrid approach of lean and agile practices to managing inventory and delivery systems
4.2 Lean transportation
The most expensive type of inventory is ______
finished goods
4.3 Lean logistics
A lean purchasing organization only buys _____ when _____.
what you need, you need it
4.4 Lean purchasing
What are 3 goals of a lean purchasing organization?
1) Prevent shortages
2) Reduce inventory where possible
3) Reduce supplier lead times
4.4 Lean purchasing
What are 3 ways a lean purchasing organization can reach it’s purchasing goals?
1) Be easy to do business with
2) Have an effective system of evaluating supplier performance
3) Work with the most reliable suppliers
4.4 Lean purchasing
What is Lewin’s Change Management Model?
1) Unfreeze
2) Change
3) Refreeze
5.1 Lean culture
Lewin’s Change Management Model:
Unfreeze
recognize where change is needed and prepare organization for the change
5.1 Lean culture
Lewin’s Change Management Model:
Change
identify activities to change
delegate specific tasks and goals
5.1 Lean culture
Lewin’s Change Management Model:
Refreeze
make the new methods permanent
5.1 Lean culture
What are 3 keys to enabling a lean mentality in the workplace?
1) Continuous-improvement mindset
2) Cross functional teams
3) Root cause analysis
5.3 Lean employees
