lean managment Flashcards
lean managment “just in time”
syncronization (perfect)
batches
a phylosophy that is based on the standardization and optimization of the process:
- flow production
- no invetory
- optimization of work space
- optimization of work
- collabotation btw human and robots
- elimination of MUDA
AIM= improving efficiency eliminating the Muda
Synchronization = the flow of products and services always deliver exactly
What customers want (perfect quality)
Exact quantities
When needed
Where needed
Lovest possible cost
Information and goods flowing rapidly
- Effitient
- Flexible
- High quality product
- Continuos flow of goods
BATCHES No production of big batches A continuos flow of diversified product Satisfy the need of the customers I must be able to switch product production with no setup prepare time
LEVEL OF INVENTORY
A high level of inventory can hide huge problem of my business (MUDA)
if i lower the inventory level i have a way to see the problem and solve it in real time
so i have to decrese the MUDA too !
THE 7 MUDA (waste)
WHAT WE CAN OPTIMIZE:
- INVENTORY :
the production shoud be a continuos flow. production to shipping whitout stoking
no owerstok = product just what u need to sell
the right ammount to satisfy the market
- WAITING: no bottleneck in the production, no mid-stoking –> continuos flow
- DEFECT: time and money to produce something worthless
I need to achive 0 defect = reliable production
I need some standard to controll over time = real time control - OVERPRODUCTION: i just need to identify and satisfy the need of the customer
produce what u going to sell - MOTION/TRASPORTATION: avoid uneccessary movment within the company and btw
customers = optimization - OVERPROCESSING: i must understand my market needs
BIC need to supply just easy and functional pens, thay don’t want
glitter and shit
inventories in lean managment
NO inventories
- > they insulate each sage from the neighbors - > they isolate also the problems, thay are not visible immediatly = not solved immediatly - > the responsibility of solving the problem is just on the people of that stage
In lean managment = if a problem occour within a stage it will be immediatly visibile in all the stages = imediate resolution = is a problem for everyone -> the problems are disappering
The production shoud be a continuos flow.
Production to shipping whitout stoking
No owerstok = product just what u need to sell
The right ammount to satisfy the market
5 principle of lean managment
1) IDENTIFICATION OF THE CUSTOMER
Must consider the needs of the customer have
What the costumer is willing to pay for
2) MAP VALUE STREAM
The goal is to use the customer's need to understand wich process contribute to achive that
If doesen't add value to the customer = waste
3) CREATE FLOW
Ensure that the flow of the remaning steps run smooth, no interruption or delay
Can improve by braking steps , reconfiguring, train employees
4) PULL PRODUCTION
A way to limit inventory and work lean
Pull flow = sistem that allign all the steps of the chain (company)
Is the customer desire (last ring) that pull the chain
(usually was a push method = lot of storage)
5) PERFECTIONIS:
Continuos improvment = create a cycle
LEAN HOUSE / TPS HOUSE
5 S
STABILITY AND STANDARDIZATION
STABILITY AND STANDARDIZATION
without a stable and standardized works flow is impossible to do improvements
5 S = a schematic for organize the work station
- SORT = choose what is neccessary and what is not (color lable)
- STREIGNTEN =
- SHINE
- STANDARDIZE
- SUSTAIN
LEAN HOUSE / TPS HOUSE
TPM = TOTAL PRODUCTION MAINTENANCE
the aim is to achive zero defects
maintenance not only when is needed (broke)
every workers has to have some knowladge and see when the machine need maintennace
mantenance = done day by day = u see if some problem rise
WE WON’T ACHIVE BRAKEDOWN
TPM PILLARS
1) Personal maintenance = every workers check his station / is use to it
2) Improvment based : the situation is improved day by day (every problem immediatly solve
3) Skeduled maintenace : don't arrive to brakedown point
4) Quality maintainance : checking in real time the quality and adress problems
5) Change the design of the product in order to be easier to mantain
6) Train workers : … ? …
7) Safety and health
8) Administration : a person incharge to check the sitation, formalize, train
water spider
He’s incharge of preparing and optimize the works station, tools, componens, matirial …
He run to differents workstationtios improoving optimizing them
Let them works always in optimal conditions without have them to move
No time wasted in searching
Must be experienced / undestand everytingh on the busines / relashionships with every one
No interuption in production flow
JUST IN TIME (JIT)
first pillar of lean house
HEIUOKA
The main obyect is to produce :
- The right product that the market demand
- At the right time
- At the right place
- At the right ammount
Avoiding the muda: waste - reduce inventories - reduce lead time
HEIJUNKA: “leveling”
Decrease the large batches and create the right mix/amount required by the customer
Product and sell directly to the customer
Requisite = reduction of set-up times
1 min exchange die = the setup time for change production should be 1 min
What can be done while the machine is still on?
second pillar of the lean house
jidoka
jidoka = automatization with a human tuch –> human inteligence to obtain inteligents machines
The machines don’t need countinuos observation of the worker
The machine can check the quality in real time:
- no more defective product
- If decrease -> human intervenction
Check the production quality in real time –> stop the line is there are defect –> solve the problem
no quality loss = to the root couse = zero defect production
poka yoke
POKA YOKE : a basic way to avoid mistakes
Simple aspect to avoid problems/defect = u can avoid defect with simple tinghs
(hole in the sink to prevent overflow / machine that check the production quality / immages …../ colors button )
Is a facilitation of the process
