Lean Foundations and Principles Flashcards
What is the purpose of Lean?
To reduce waste in the value stream and provide maximum value to our customers; do more with less.
What are the Lean methodologies?
- Just-in-time
- Poka-Yoke
- Kanban
- Value-stream mapping
What is a Value Stream?
The series of activities that a organisation performs in order to deliver products and services.
What are the main components of a value stream?
- The flow of materials
- The transformation of inputs to outputs
- The flow of information
What is 5S?
1.Sort
2. Set in Order
3. Shine
4. Standardise
5. Sustain
In the 5S system, what does Sort mean?
Remove unneeded items, clean up the work area.
In the 5S system, what does Set in Order mean?
Arrange items for ease of accessibility - a place for everything and everything in its place.
In the 5S system, what does Shine mean?
Cleaning the work area and equipment.
In the 5S system, what does Standardise mean?
Develop checklists, standards and work instructions to keep the work area clean and orderly.
In the 5S system, what does Sustain mean?
Sustain the cleanliness and organisation of the work area by embedding the process.
What is Kaikaku?
Breakthrough improvement, or kaizen event.
What is Kaizen?
Change for improvement.
How long does Kaikaku last?
3 to 5 days.
What is a “Pull System”?
A component of Just in Time, where a process produces only when there is pull from the subsequent process.
What is Just In Time?
An inventory strategy where the delivery of material or product happens only at the exact time and place it will be used.
What is kanban?
A system for improving system control by ensuring timely movement of products and information.
What is Poka-Yoke?
A system for built in “mistake-proofing”, or “error-proofing” to prevent errors.
What is Standard Work?
A tool that defines the interaction between person and machine with three components;
- Standard time
- Standard inventory
- Standard sequence
What does the Standard Work tool do?
Helps train new operators and reduce variation in the process.
Lean experts define a process step as value added if?
- The customer recognises the value
- It changes the product
- It is done right the first time
What is muda?
Waste
What are the types of muda?
- Overproduction
- Excess motion
- Waiting
- Inventory
- Excess movement of material
- Defect correction (rework)
- Excess processing
- Lost creativity (underutilisation of resource skills)
