Lean Production Flashcards
What is lean production?
Lean production occurs when managers reduce waste and therefore operations become more efficient.
How does lean production aim to reduce waste?
• Improving quality and so reducing the number of items that need to be reworked, thrown away or fixed
• Reducing the amount of inventory held
• Reducing how long items are idle for.
• Reducing the time between stage of processes
What are some forms of lean production?
• Kaizen
• Andon
• Changes to the layout of a store or factory and changes to the process used to make it more efficiently
What is Kaizen?
• Kaizen is an approach which values continuous improvement.
• Major changes over time can occur as a result of small changes made regularly.
• A mindset of always thinking of ways to improve efficiency.
What is the Kaizen approach (6 steps)?
1) Brainstorm/standardise
- Think of ways to make repeatable processes that are efficient
2) Measure
- Ensure these processes are efficient using quantifiable data.
3) Compare
- Compare the data from your measurements
4) Innovate
- Search for new and improved ways to do these processes
5) Standardise (again)
- Once everyone is satisfied with a tested new idea or process, make it repeatable
6) Repeat
What are the pros of Kaizen?
• Strengthening teamwork
• Improved leadership skills
• Improved efficiency
• Improved best practises
• Improved employee satisfaction
• Improved safety
• Reduced waste
What are the cons of Kaizen?
• Implementing company-wide changer is hard
• Additional training
What is Andon?
On a production line Andon cord is present above the process. If there is a problem the Andon cord is pulled and production stops.
Flashing lights highlight where the problem has occurred and everyone goes to this point to understand what happened.
What are the pros of Andon?
• Visibility and transparency in the production process
• Increase productivity and efficiency
• Decreased waste
• Reduces costs and downtime
• Improved quality
• Employee empowerment
What are the cons of Andon system?
• Initial investment is costly
• Decision-making
What is a lean organisation?
Lean organisations try to ensure that the systems and rules in place are the essential ones. That meetings are productive and do not take up too much time, and not over communication.
What are the difficulties of adopting lean production?
• No Inventory if there is ever a disruption to production
• If employees strike or if suppliers fail to deliver, operations will come to a halt
- May need multiple suppliers to avoid this problem
• Employees need to be independent and be trained to a high quality.
How do technological developments help businesses?
• More flexible to customer needs
• Reduce costs by having more efficient processes with less errors
• Be innovative
However, managers have to:
• Have the finance to invest
• Have the training
• Understand and manage the impact on other functions.
