Lean Production Flashcards
Kaizen
A continual improvement approach of constantly introducing small changes in order to improve quality and/or efficiency.
Advantages
Benefits to the entire organisation
Teamwork improvements
Requires team leader so leadership skills develop
Disadvantages Difficult to initiate Friction btwn stakeholders Training requirements sometimes Expensive Everyone must contribute
Just in time
Buying the components immediately b4 they’re needed
Product runs are short Less space is required Better for smaller companies Save resources Lower storage costs Prevents over production
Disadvantages:
Risk running out of stock
Planning is required to rely on suppliers arriving on time
Loss of control when dealing with suppliers
Cell production
To move as quickly as possible, make a wide variety of products, make minimal waste. Production carried out in cells.
Advantages
Workers are motivated bc sense of ownership and teamwork
Better 4 environment
Disadvantages
More skilled workers may be more expensive
May not allow intense use of machines
High set up costs
Time based management
Reduces level of time in production, production systems need to be flexible to be effective, requires flexible, multi skilled staff and mutual trust btwn workers and managers
Advantages Low stress (no work from home) Maximised efficiency No time wasted Use spare time for other thing s
Disadvantages
Non-clear objectives
Demotivating
Micro-management can be stressful
Total Quality Management (TQM)
aims to have no defects and total customer satisfaction
Advantages Cost reduction Moral raising Customer satisfaction Defect reduction Motivated workers
Disadvantages
Higher costs - quality checks may take longer
Staff need specialist training
Takes time to initiate
If there is a delay in production nothing can move forward until resolved
Quality circles
Voluntary scheme where employees meet within the working day to consider problems affecting their work and quality
Advantages Manager gain a gr8er awareness of employers probs Improved communication Improved motivation Inc productivity and quality
Disadvantages Time consuming Conflict of opinions Balance departments and no. Of employees May not lead to any changes
Kanban
Inventory scheduling system that allows companies to stock only needed components in the production and distribution stage. Balances demand with a available capacity. Bar codes and lights are the typical way of indicating where thing are in the production line.
Advantages Ensures quality control Reduction of wasted work Inc productivity Inc efficiency
Disadvantages
Less effective in resource situations (shared among all all products) product mix or demand changes may cause problems.
Quality misuses
Production flow problems
Jidoka
(Automation) discover abnormality, stop the process, fix the problem, investigate and stop root cause.
Advantages
Bad practices aren’t spread within the business
Employees have responsibilities = motivated
Chance of equipment breakdown
Disadvantages
Reliant on employees to notice problems
Lots of downtime to check machines
May take a while to find root cause and production is slowed/stopped to find it
