Lean Production - Jidoka, Kaizen, Time Based Competition, JIT, Cell Production, Ergonomics, Quality Circles

Question 1

whats lean production

Answer 1

an approach where all employees are involved in putting into operation a series of working practices that will help the business to meet the demands of the consumer in a efficient and effective manner

requirements of the consumer are likely to be met - reliable quality and delivered on time

a whole business approach to achieveing and maintaining a competitive product in the highly competitive market

concentrates in eliminating waste - materials + time + energy - reduce costss and have a competitive edge

anything that helps to reduce the time is the lean approach

Question 2

Time- based competition

Answer 2

attempt to reduce the time taken BETWEEN THE GENERATION OF THE IDEA for a product and it GOING INTO PRODUCTION (LEAD TIME)

can be sped up by the usage of CAD and virtual design techniques - any new designs can be tested virtually before the actual product is put into production - no need to built protypes

:) saves time and cost of building protypes

Question 3

TQM

Answer 3

considers the efficient usage of all the resources used within the production process - direct or indirect to the actual production process

vital that all employees are responsible for the well-being of a business - not just those that are in production

employees taking responsibility for the work they do

emphasis is on finding ways to prevent mistakes rather than inspect for mistake sorry

Question 4

Jidoka

Answer 4

process for building into the production process - an ability to detect + reject faulty goods and components at the earliest possible moment in the good’s production

essential to try keep the production line operating - if it stops = DOWNTIME which is expensive and to be avoided at all costs if possible

an aid to prevent defects occuring - may mean production process has to be stopped

Question 5

Andon Lights - Jidoka

Answer 5

usually displayed alongside every line - management and supervisors to check the progress of each section on the assembly line

at a particular work station and the lights flash amber or red to get their attention and get a quick response to that part of the line - keep the line moving and no downtime

Question 6

Kaizen

Answer 6

a philosophy which means improvements ain quality are continuous and not just something thats occasional

‘continuous improvement’

achieved better if all employees are encouraged to takw part in the process not just the management

improving one part of the process means improving in other parts of the process - save several seconds in early parts of the production line
- find improvements further down the production line so its a smooth flow

Question 7

Kaizen and employees

Answer 7

jobs may be affected with employees jobs being affected:

• reluctant to make any suggestions on how to improve the production process for fear of losing their jobs
• can put pressure on employees - stress or accidents = JOB ROTATION as a solution

Question 8

Quality and Quality Circles

Answer 8

to maintain the kaizen approach

voluntary scheme where employees (4-10) are allowed to meet in working hours to discuss problems related to working environment and workstations

also aim to create solutions to problems and pass on these to management - motivational benefits for employees being invovled + improve productivity in some cases

Question 9

JIT

Answer 9

method whereby levels of stock are kept low
- in order to reduce the amount of space required for storing stock

ordering stock in small qualities but with more frequent deliveries means that the business can hold less stock and save costs

Question 10

Kanban (to help JIT operate effectively)

Answer 10

helps to organise the slow of components onto the production line at the right place at the right time

as the components are used, the level of stock by the line falls like a vending machine

Question 11

JIT advantages

Answer 11

• reduced costs due to less stock being held
• less cash tied up in stock
• less stock held so lesslikelihood of damage or out of date = wasted

Question 12

JIT disadvantages

Answer 12

• set up cost in order to operate (Kanban technology)
• any serious errors within the production system may affect the level of production as there is a little spare stock to utilise
• less stock being held but still delay from suppliers etc. can hault production

Question 13

Cell production

Answer 13

• form of teamwork = employees placed in different teams with each team responsible for a particular part of the production process
• responsibility includes control of quality for their particular part of the production process and ensuring that the parts are delivered to their area or part of the process at an acceptable standard

also responsible for health and safety to that area + deciding who preforms the taks and when they are to be completed
- can rotate their jobs within the cell to enhance job satisfaction
as long as process is completed in time for next stage and to the right standard.

Question 14

Ergonomics

Answer 14

looks at the relationship between the employee and the capital equipment (machine or tool) being used

effective ergonomic design: one where the minimum amount of time is wasted in using the machine or equipment
- things hung on springs so when workers are done can let go of it when they’ve used that tool to complete their task - save valuable seconds not having to walk places to get tools and having all you need close around you