Lean Operations Flashcards
What is the core philosophy of TPS?
Eliminate waste
What are the goals of TPS?
-Reduce cost
-Improve quality
-Improve timeliness
What are the core principles of TPS?
-Just-In-Time
-Jidoka
-Heijunka
-Andon
-Poka-yoke
-Kaizen
What is JIT and what is its main objective?
-Make and deliver products according to exactly what is needed
-This is to minimise WIP inventory
What is the benefit of reducing WIP inventory?
It increases problem visibility
What are the 3 JIT practices?
-Continuous Flow
-Takt Time
-Pull System
What are the benefits of continuous flow?
-Reduces WIP inventory
-Reduces waiting time
-What are the requirements to implement a continuous flow process?
-Reduce setup time
-Create a layout that reduces transport
What is Takt Time?
-Produce at a rate in line with demand
-Takt time= Total production time/ customer demand
What are the benefits of Takt Time?
Reduces finished goods inventory
What is a push system?
Materials are pushed downstream in a supply chain
What is a pull system?
-Materials are pulled upstream from downstream workstation
-This is triggered by a downstream demand signal
What are the benefits of a pull system?
-Reduces WIP inventory
What is Heijunka?
-Production of mixed products is done in a sequence of small batches
What are the benefits of Heijunka?
-Smoothed production schedule
-Reduces inventory
-Synchronisation with customer demand
-Smoother demand on the upstream processes and suppliers
-Balances the use of labour and machines
What are the requirements of Heijunka?
-Short setup and changeover times
What is Jidoka?
Quality control
What are the Jidoka practices?
-Quality at source
-Human-machine separation
What is quality at source?
-Inspect quality during the production process rather than at the end
-Never pass on defective units to the next process
-This minimises rework
What is Andon?
A system that displays and alerts operators and managers of real time status and problems of a process or product quality
What are the benefits and drawbacks of Andon?
-Lower risk of snowballing waste due to defects
-Cost depends on the duration of the line stop
-Therefore processes should be in place to ensure the the stop time is minimised
What is Poka-Yoke?
-Mistake proofing
-Components are designed in such a way such that it is impossible to assemble them incorrectly
What is human-machine separation?
-Work is executed with different timelines for the people and machines involved
-If the machines are fully automated, this means the people can do other tasks while the machines work
What is Kaizen?
Engage every employee to continuously improve the process
