Lean Principles and Philosophy Flashcards
What characteristics belong to lean?
- Lean management supports the concept of continuous improvement.
- Continuous improvement focuses on processes and effectiveness.
- It includes methods, ways of thinking and tools to optimize processes.
What is TOS?
Framework and tools to engage all employees in moving the organization towards lean
Lead time- also known as “throughput time”
Refers to the time period from placement of an order until the finished product is handed over to the client. This includes all process times, as well as all waiting times (warehouse, inventories ).
What are the 7 “rights” in Just-in-time?
right information right product right quality right time right amount right place, and reasonable costs
Kaizan means…
Kaizen is a Japanese philosophy of life and work. Its goal is to strive for continuous improvement, also known as the Continuous Improvement Process (CIP).
This triggers small improvements that are always growing and being pursued, but never stopped.
Jidoka means…
“intelligent automation”, stopping a process whenever an anomaly occurs.
That way mistakes are not passed on to the next process!
Hence problems can be solved right where they occur and quality is produced.
The principles of Jidoka can be applied, beyond systems and machines, to any process, including manual ones: resolution of customer complaints, identification of material defects, etc
What are the 9 lean principles?
Take the long view, go and see, imagine you are the customer, only empowered people produce powerful performance, share openly/borrow proudly, choose the process focus, learn from mistakes, respect partners, keep it simple.
Quality
Degree up to which a set of inherent (i.e., intrinsic) characteristics meets requirements.
Q-Alarm
Possibility for the worker to get fast and reliable support to rework all defects within the takt.
- -Support for rework needed
- Supporter finishes the work while the worker moves to the next vehicle
- The worker needs help
Q-Stop
If the problem can’t be solved by the foreman or supporter within the standardized work cycle, the conveyer will stop.
–Problem can’t be solved in the work station
What is a fixed position stop?
Here the production conveyor stops at a fixed position that coincides with the end of the work station and the end of a standardized work cycle.
Poka Yoke means “error avoidance”, what are three principles that can be utilized?
Mistake proofing
- Contact principle
- Fixed-value principle
- Step-by-step principle
How many losses do we consider in a business system?
3
What is the goal of a lean organization?
- Elimination of waste- Shortest processing times, Increased added value
- Reduction of variability- High availability of machinery and equipment, Standards are put into practice and optimized, High maturity level of products, High process capability
- Increased flexibility- Flexibility in terms of layout and materials handling technology, Flexibility in terms of machinery and systems, Flexibility in the organization
8 types of waste
TIMWOOD+U
Transport, Inventory, Motion, Waiting, Over-processing, Overproduction, Defects + Unutilized people
Which type of waste is the worst?
Overproduction is the worst type of waste, as it leads to further waste (in the case of overproduction, too much of everything is manufactured, and all other types of waste also increase as a result).
Variability leads to …
Dissatisfied customers or higher costs. Ex material, information
Inflexibility leads to …
Inflexibility is expressed in the inability to meet the customer’s requirements (whether it’s a service or a product).
You have a loss of efficiency due to differences between customer demand and the supply of resources.
Underutilization resources or overload and dissatisfied customers or higher costs.
PDCA stands for?
Plan– Identify need for action. Plan/design task.
Do– Implement solution
Check– Evaluation of results
Act– Act and go for standardization and sustainability
and/or adjust your plan and try again
What statements are true about PDCA?
The PDCA cycle helps to improve a process.
The PDCA cycle is repeated again and again.
The PDCA cycle can also be thought of as Plan - Sprint - Review - Retro.. used in an agile working environment.
Value stream
- A value stream consists of all the activities/ business processes that are necessary to fill an order.
- Consequently it starts at the customer and ends
at the customer. It can involve production, product development, customer service, a service rendered, etc. - Analysis of the entire value stream enables optimization of the overall system
Why do we need to look at the value stream?
To analyze the actual state, to make wastes transparent
TOS as our Production System: Leadership and Employees
combine leadership with deep process understanding
TOS as our Production System: Standardize Processes
Create the basis for creative improvement with standardized work
TOS as our Production System: Stability and Quality
Create simple, robust processes, technology and products
TOS as our Production System: Flow and Value Stream
Create value without delay
TOS as our Production System: Continuous Improvement
Strive gradually for perfection
Project sponsor
Initiates the projects and makes decisions
Project leader
Owns the project content and is in control of the project. The project leader is in control of the project. She/he manages the project team, even if the project team is not a team in the organizational context.
Experts from the line function
Know the area; plan and implement the operative work on site
Consultants
Act in different roles while working with the line function
The results of Jidoka are:
- Quality right from the start and in every process starting with design and extending right up to the customer.
- - quality stop principle
- - andon
- - poka yoke - Manual and machine work are separated to increase working productivity.
Poka Yoke Avoidance
Avoidance means no transfer of an error.
It’s also called “Soft” Poka Yoke, because the error can still occur.
Poka Yoke Prevention
Prevention means an error cannot occur.
It’s also called “Hard” Poka Yoke, because the error can not occur.
Poka Yoke “Contact Principle”
Identifying parts through typical characteristics.
Poka Yoke “ Fixed Value Principle”
Identifying deviations from fixed values
Poka Yoke “Step-by-step Principle”
Identifying deviations from standard processes.
Every business consists of 3 steps..
Input, System, Output
Losses in these 3 areas have an impact on performance and output
Typical improvement direction
- To start with, the process is very variable and above the target value.
- Standardization reduces the process variability and steers the process more strongly in the desired direction.
- Kaizen measures deliver further process improvements. Variability is minimized and the targeted average cycle time is attained.
Value Stream Mapping
Value stream mapping makes it possible to record the actual status of a process along the added-value chain and depict it with standardized symbols. It is the basis of value stream-oriented implementation activities and it generates in-depth process understanding.
Value Stream Design
In value stream design visions and target images are developed on the basis of value stream mapping and then implemented.
Thinking in processes” / reflecting a value stream can help if …
- Process issues need to be fully understood before implementing effective measures.
- Quality of deliverables needs to be ensured under variable conditions.
- Root causes for problems are unclear among stakeholders.
What are the two building blocks that the Daimler TOS is made up of?
- Lean management philosophy: This is made up of 6 principles. “Gives you the necessary training and support to lead and act leanly.”
- TOS methods: These can be divided into 5 categories and have different tools. “Use the right tools at the right time and in the right place.”
