Lean Operations Flashcards

1
Q

What are the two types of scale production?

A

Craft production

Mass production

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2
Q

What constitutes craft production?

A

Highly skilled workers

Simple flexible tools

Small quantities

Customised goods

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3
Q

What constitutes mass production?

A

Low skilled workers

Specialised tools

Large quantities

Standardised goods

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4
Q

What is lean operations?

A

Eliminate waste

Involve everyone

Continuous improvement

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5
Q

What are the advantages of mass production over craft production?

A

Large quantities of goods

Cost per unit reduces as volume increases

Replacing parts is easier

Economies of scale are applicable

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6
Q

How does lean operations improve business?

A

Removes waste

Reduces timeline

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7
Q

What is the AUTOMATION economy of scale?

A

Standardise and automate

Reduce manufacturing costs

Lower, more competitive prices

Growth in market share

Increase scale of production

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8
Q

What is the INTEGRATION economy of scale?

A

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

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9
Q

What are the market requirements?

A

Shorter time to market

Shorter development time

On time delivery

High quality and reliability

Reduces cost

Increased variety and complexity

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10
Q

What are the market conditions?

A

Markets are uncertain and unpredictable

Need to organise to thrive

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11
Q

What are the strategic focusses?

A

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.

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12
Q

What is JIT?

A

Just in time

Meet demand instantly

Perfect quality

No waste

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13
Q

What are the production flow activities and their shapes?

A

Operation - circle

Movement - arrow

Inspection - square

Delay - D shape

Storage - inverted triangle

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14
Q

What are the seven types of waste?

A
Overproduction
Waiting time
Transport
Process
Inventory
Motion
Defects
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15
Q

What is operations waste?

A

Producing more than is immediately needed by the next process.

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16
Q

What is waiting time waste?

A

Time lost waiting for tools, materials, or other resources.

17
Q

What is transport waste?

A

Movement which does not add value to the product.

18
Q

What is process waste?

A

Processes which are not necessary but are part of product design.

19
Q

What is inventory waste?

A

Ineffective operations functions being hidden by excess inventory.

20
Q

What is motion waste?

A

Operators being, or appearing to be, active but not actually performing value adding processes.

21
Q

What is defective goods waste?

A

Products which do not match specification, which must be re-worked or scrapped.

22
Q

What are the three focal points of continuous improvement?

A

Employee involvement

Flow of production

Quality

23
Q

What is the JIT approach to capacity utilisation?

A

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

24
Q

What are the lean/JIT objectives for production (related to seven wastes)?

A
Zero rejects
Zero setup time
Zero inventory
Zero handling
Zero breakdowns
Zero lead time
Batch size of one
25
What are the types of production layout?
Line Cell Fixed
26
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 ```
27
What is TPM?
Total productive maintenance
28
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
29
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
30
What are the lean manufacturing types of production?
Continuous Repetitive Intermittent
31
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
32
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 ```
33
What are the 5 "R"s?
Redesign Reduce Recover Recycle Remanufacture