Lean manufacturing

Question 1

What is Socio-technical system?

Answer 1

Approaches production environment as a system as two integrated parts: social and technical.

• Focuses more on giving individuals control of their work, they are given more responsibility for tasks

Question 2

What is LP?

Answer 2

Lean production

• Emerged from the Toyota production system, aiming to reduce waste in the production process and enhance flow and perfection by implementing continuous improvement

Question 3

LP can be describes by 5 principles, what are these?

Answer 3

1. Specify value: Define value of product subject to each customer
2. Identify value stream
3. Make the value-creation flow: create flow without obstacles or interruptions
4. Embrace pull: demand should come from the customer, otherwise waste!
5. Strive for perfection through continuous improvement

Question 4

How does STS and LP differ from Scientific management?

Answer 4

Both STS and LP gives more control and responsibility to the workers (focus more on efficiency)
STS: workers are in control of their tasks
LP: Workers are in control of the production line and manages the flow in production. However still defined tasks.

The scientific management philosophy: doesn’t allow workers to have control. The worker is expected to have an individual and well-defined work task
- Performance is based on output (more effectiveness)

Question 5

What is continuous improvement?

Answer 5

In small steps improve the production: both in product and process

• Usually actions in production stage considering the process or product
• Deming cycle: Plan, do, check, act (for quality improvement)

Question 6

What are the task areas of traditional quality management?

Answer 6

Plan, do, check, act

Question 7

How has Lean Production changed they way of viewing profit and pricing?

Answer 7

Before: Price= cost + profit
- If cost increases, the price is raised to maintain profit

After: Profit= Price-cost
- If market fixes the price, the only way to maintain profit is by lowering the cost
- A more competitive approach

Question 8

What is MUDA?

Answer 8

A term maning “waste”

• Refers to any activity or process that consumes resources but does not add value to the final product

7 types of MUDA:

1. Transportation
2. Inventory
3. Motion
4. Waiting (bottleneck)
5. Over-processing
6. Over-production
7. Defects

Question 9

What is the 5 S method steps?

Answer 9

Method for establishing routines to minimize waste in production

1. Sort
2. Set in order
3. Shine
4. Standarize
5. Sustain