Lean management Flashcards
What is the definition of Lean management?
A systematic approach focused on eliminating waste, improving efficiency, and delivering value to customers.
What is the primary objective of Lean management?
To create smooth, efficient workflows that reduce costs and delays.
Where was Lean management developed?
In the Toyota Production System (TPS).
List key benefits of Lean management.
- Faster customer response times
- Higher product quality
- Lower operational costs
- Reduced waste in all forms
What are the four core principles of Lean Operating Systems?
- Eliminate Waste
- Continuous Improvement (Kaizen)
- Just-in-Time (JIT) Production
- Respect for People
What does ‘Eliminate Waste’ mean in Lean management?
Identify and remove non-value-adding activities.
What are the types of waste (Muda) identified in Lean management?
- Defects
- Overproduction
- Waiting
- Transport
- Over-processing
- Inventory
- Motion
What is Continuous Improvement (Kaizen)?
Encouraging small, continuous changes for efficiency with employee participation.
What is Just-in-Time (JIT) Production?
Producing only what is needed, when needed, to avoid excess inventory.
What does ‘Respect for People’ entail in Lean management?
Empowering employees to suggest improvements and focusing on teamwork and safety.
What are the 5S principles in Lean management?
- Seiri: Sort
- Seiton: Set in Order
- Seiso: Shine
- Seiketsu: Standardize
- Shitsuke: Sustain
What is the purpose of Visual Controls?
To track performance using tools like charts, labels, and color codes.
What does Single-Minute Exchange of Dies (SMED) aim to achieve?
Reduces setup/changeover times in production.
What is the difference between Batch Processing and Single-Piece Flow?
- Batch Processing: Producing in large groups (increases inventory)
- Single-Piece Flow: Producing one item at a time (reduces waste)
What is Total Productive Maintenance (TPM)?
A method to ensure machines operate at peak efficiency through preventative maintenance.
What is Lean Six Sigma?
A combination of Lean (eliminating waste) and Six Sigma (reducing process variability).
List key features of Lean Six Sigma.
- Customer focus
- Cost savings
- Root cause analysis for problem-solving
What are key practices in Lean Manufacturing?
- Clean and organized workspaces
- Efficient layouts
- Multi-skilled workers
- No inspection stations
How does Timken Company use Lean techniques?
- Eliminate waste
- Increase speed with flexible manufacturing
- Improve quality with Six Sigma tools
Give an example of Lean application in service organizations.
Southwest Airlines reduces turnaround time using standardized processes.
What is the definition of Just-in-Time (JIT) Systems?
Produces only what is needed, avoiding excess inventory.
What is the difference between Push and Pull Systems?
- Push System: Produces inventory in advance based on forecasts
- Pull System: Produces when there is demand
What is the purpose of the Kanban System?
To signal when new inventory is needed, ensuring smooth production flow.
What are the benefits of Just-in-Time (JIT)?
- Minimizes waste and inventory costs
- Synchronizes production with demand
What are the benefits of JIT in service organizations?
- Reduces order processing time
- Optimizes office space and workflow
- Increases productivity and profits
What may be a limitation of JIT in human-centric services?
May reduce flexibility.
Define the term ‘5S’.
Workplace organization technique.
What does ‘Kanban’ refer to?
Inventory control system.
What is meant by ‘Lean Operating Systems’?
Focused on eliminating waste.
What does ‘Lean Thinking’ emphasize?
Efficiency and continuous improvement.
What is Takt Time?
The rate at which products must be made to meet demand.
What is the purpose of Single-Piece Flow?
Producing one item at a time.
What is Total Productive Maintenance (TPM)?
Maintenance method to prevent breakdowns.
What do Visual Controls indicate?
System performance.
What is the summary of Lean Management?
Aims to eliminate waste and improve efficiency.
What do JIT Systems optimize?
Inventory management.
How does Lean Six Sigma combine different methodologies?
Combines waste reduction with quality improvement.
What do Visual Controls and Kanban improve?
Workflow visibility.
Is Lean applicable in both manufacturing and services?
True.
