Lean Quiz - Devall Notes Flashcards

1
Q

Standardization

A

current state definition of all system elements

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2
Q

Heijunka

A

scheduling mechanism controlling mix and leveling demand at single point in process
- also known as production smoothing

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3
Q

Kanban

A

method to allow material pull where one piece flow cannot work
- inventory and production control

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4
Q

Jidoka

A

machines that can detect and halt the process until a fix is made - build quality in station

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5
Q

Andon

A

ability of an operator to identify a defect - requires standard response for team

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6
Q

Quality at the source

A

MO CO MOO

no inspection

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7
Q

Continuous Improvement Cycle

A

credited to Schewhard
developed by Deming
PDCA (plan-do-check-act) - iterative 4 step management method for control and continuous improvement of processes/products

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8
Q

3 building blocks that shape committment to continuous improvement

A

challenge - long term vision
kaizen - cont. improvement
genchi genbutsu - go to source to find facts to make corrections

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9
Q

Ford - keys to success

A
  • interchangable parts
  • moving conveyor to bring car to employee
  • specialized and balanced labor
  • vertical integration
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10
Q

Ford - weakness of mass prod.

A
  • limited goals
  • end of line repair
  • low employee morale
  • dedicated machines only build 1 part
  • low product variety
  • low wage led to reduced turnover
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11
Q

GM perfects mass prod.

A
  • product variety
  • decentralization
  • division of professional labor
  • standardization of component parts
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12
Q

GM - still weaknesses

A
  • no improvement of labor issue

- full of hidden waste

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13
Q

Mass production issues

A
  • absenteeism
  • work assignment restrictions
  • lots of hidden waste
  • holding back knowledge/effort
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14
Q

Sakichi Toyoda

A
  • invented automatic power loom — JIDOKA

- developed 5 Why Technique

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15
Q

Kiichiro toyoda

A
  • implemented Chain Driven Assembly Line

- initial efforts for JIT

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16
Q

Eiji Toyoda

A

credited with JIT and Jidoka implementation

17
Q

Taiichi Ohno

A
  • defined 7 wastes - MUDA
  • refined JIT with Kanban
  • refined jidoka adding Andon
18
Q

Shigeo Shingo

A
  • developed SMED

- Poke Yoke - refined error proofing strategies

19
Q

how to eliminate waste

A

in order to eliminate waste, you must set standards so that you know what your benchmarks for improvement are - must re-standardize continuously

20
Q

TPS Lean House - most important aspect

A
  • employee involvement
21
Q

After Sales collapse, what did company agree to?

A
  • lifetime employment
  • wages tied to seniority
  • wages tied to company profitability through bonuses