Lean Production Flashcards
What is lean production
Based on Japanese theories of management designed to reduce waste within a business
What does the term waste refer to
Any process that does not add value to a product
Give examples of waste in a business that isn’t adding value to production
1 raw materials not being used
2 work in progress sitting in a warehouse waiting to be used
3 finished item sitting in a warehouse waiting to be delivered
What is the aim of lean production
Increase productivity and reduce costs
What systems must be adopted for lean production
1 change of business approach away from traditional function
2 just in time
3 kaizen
4 cell production
5 time based management methods
What is just in time
Tries to ensure raw materials are received and products are made when there is a demand for parts for the production
“If it isn’t wanted don’t order it if it isn’t sold don’t make it
What needs to be in place for just in time to be successful
1 management understanding - 1st stage of just in time process there needs to be a understanding of the production process
2supplier relationships - need to have strong effective communication systems so suppliers know when stock is needed before it runs out
3 Kanban - use of order cards to ensure regular and timely supply of component
4 employee involvement - a people centered approach from management. Employees must be trained to use the systems of lean production and understand their role.
4 customer relations - final part - orders can be placed electronically so finished product goes straight for delivery and not stored in a warehouse which can lead to loss of value
What is kaizen
Japanese word meaning continuous improvement
2 how it works in business is based on groups of workers who have a stake in the production process
3 groups meet regularly to discuss problems and suggest solutions
What was British business like before kaizen
1 Improvements in quality of output were made in large one off steps often forced on a business because of actions of competitors -
2 so business playing catch up and as soon as they made improvements to keep up with competitors eg installing new equipment competition had moved on again
What are the key elements of kaizen
1 all employees should be asking how can i do better
2 kaizen doesn’t ignore need for new technology or capital investment but that these are not the only methods to achieve competitiveness
3 a motivated workforce
4 a management with belief in its workforce
5 a trained workforce
6 effective communication systems
7 security of jobs
8 management has a clear understanding of production process
What are the benefits of kaizen
1 improved labour relations
2 increased competitiveness
3 reduction in wast
4 less large scale investment
5 improved motivation
6 increased productivity
7 improved quality
What is cell production
Cell production is divided into groups of workers involved in related tasks (cells)
2 workers are trained so they can complete a number of tasks in the cell and allow job rotation
What are time based management methods
Emphasis on reducing time taken in production process
Which concepts are used in time management methods
1 just in time
2 CAD
3 CAm (computer aided manufacturing)
4 critical path analysis
5 simultaneous engineering
What is simultaneous engineering
Carrying out processes at the same time
