Lean Operations Flashcards
What are the two types of scale production?
Craft production
Mass production
What constitutes craft production?
Highly skilled workers
Simple flexible tools
Small quantities
Customised goods
What constitutes mass production?
Low skilled workers
Specialised tools
Large quantities
Standardised goods
What is lean operations?
Eliminate waste
Involve everyone
Continuous improvement
What are the advantages of mass production over craft production?
Large quantities of goods
Cost per unit reduces as volume increases
Replacing parts is easier
Economies of scale are applicable
How does lean operations improve business?
Removes waste
Reduces timeline
What is the AUTOMATION economy of scale?
Standardise and automate
Reduce manufacturing costs
Lower, more competitive prices
Growth in market share
Increase scale of production
What is the INTEGRATION economy of scale?
Continuous improvement and more integration
Reduced cost and higher quality/flexibility
Market growth through responsiveness
Greater demand for product variety and fewer small batch sizes
More intelligent technology and operating data
What are the market requirements?
Shorter time to market
Shorter development time
On time delivery
High quality and reliability
Reduces cost
Increased variety and complexity
What are the market conditions?
Markets are uncertain and unpredictable
Need to organise to thrive
What are the strategic focusses?
Achieving a balance between stability in uncertain circumstances and responsiveness to change.
Achieving continuous improvement, profitability, and growth.
Adaptability in proficiency when subject to disturbances.
What is JIT?
Just in time
Meet demand instantly
Perfect quality
No waste
What are the production flow activities and their shapes?
Operation - circle
Movement - arrow
Inspection - square
Delay - D shape
Storage - inverted triangle
What are the seven types of waste?
Overproduction Waiting time Transport Process Inventory Motion Defects
What is operations waste?
Producing more than is immediately needed by the next process.
What is waiting time waste?
Time lost waiting for tools, materials, or other resources.
What is transport waste?
Movement which does not add value to the product.
What is process waste?
Processes which are not necessary but are part of product design.
What is inventory waste?
Ineffective operations functions being hidden by excess inventory.
What is motion waste?
Operators being, or appearing to be, active but not actually performing value adding processes.
What is defective goods waste?
Products which do not match specification, which must be re-worked or scrapped.
What are the three focal points of continuous improvement?
Employee involvement
Flow of production
Quality
What is the JIT approach to capacity utilisation?
Focus on producing only when needed
Low capacity utilisation means no surplus in inventory
Low inventory means problems are exposed and solved
Fewer stoppages due to product defects
What are the lean/JIT objectives for production (related to seven wastes)?
Zero rejects Zero setup time Zero inventory Zero handling Zero breakdowns Zero lead time Batch size of one
What are the types of production layout?
Line
Cell
Fixed
What are the criteria for cell design?
Maximum visibility Maximum flexibility Maximum co-ordination Maximum use of volume Maximum accessibility Minimum distances Minimum handling Minimum discomfort Maximum security Inherent safety Unidirectional flow Visible routes
What is TPM?
Total productive maintenance
What does TPM achieve?
Operators care for processes - correct operation, detection of problems, perform maintenance, collect data
Maintenance’s roles change - training operators, long-term planned maintenance, condition monitoring
Emphasis change - reliability, operator involvement, equipment care
How are layouts designed?
Arranged to achieve logical flow
Equipment is close to reduce movement needed
Shaped (such as U) to improve visibility and teamwork
Emphasising simplicity, flow, visibility, and morale
What are the lean manufacturing types of production?
Continuous
Repetitive
Intermittent
Why does JIT prefer small machines for operations?
Easier to move
Faster setup
More flexible scheduling options
Cheaper tools
Planned maintenance is easier
Fewer setups needed
What are the basic working practices of JIT?
Disciplines and standards Flexibility of processes Equality of conditions Creativity Quality of working life Development of personnel Ability to intervene
What are the 5 “R”s?
Redesign
Reduce
Recover
Recycle
Remanufacture
