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
What are the 7 sources of waste?
-Overproduction
-Waiting
-Transport
-Overprocessing
-Inventory
-Rework
-Motion
How does reducing inventory expose problems?
-It exposes defects quickly and allows the determination of the root cause of the problem
-Causes short term losses in throughput
