Lean Quiz - Devall Notes Flashcards
Standardization
current state definition of all system elements
Heijunka
scheduling mechanism controlling mix and leveling demand at single point in process
- also known as production smoothing
Kanban
method to allow material pull where one piece flow cannot work
- inventory and production control
Jidoka
machines that can detect and halt the process until a fix is made - build quality in station
Andon
ability of an operator to identify a defect - requires standard response for team
Quality at the source
MO CO MOO
no inspection
Continuous Improvement Cycle
credited to Schewhard
developed by Deming
PDCA (plan-do-check-act) - iterative 4 step management method for control and continuous improvement of processes/products
3 building blocks that shape committment to continuous improvement
challenge - long term vision
kaizen - cont. improvement
genchi genbutsu - go to source to find facts to make corrections
Ford - keys to success
- interchangable parts
- moving conveyor to bring car to employee
- specialized and balanced labor
- vertical integration
Ford - weakness of mass prod.
- limited goals
- end of line repair
- low employee morale
- dedicated machines only build 1 part
- low product variety
- low wage led to reduced turnover
GM perfects mass prod.
- product variety
- decentralization
- division of professional labor
- standardization of component parts
GM - still weaknesses
- no improvement of labor issue
- full of hidden waste
Mass production issues
- absenteeism
- work assignment restrictions
- lots of hidden waste
- holding back knowledge/effort
Sakichi Toyoda
- invented automatic power loom — JIDOKA
- developed 5 Why Technique
Kiichiro toyoda
- implemented Chain Driven Assembly Line
- initial efforts for JIT
Eiji Toyoda
credited with JIT and Jidoka implementation
Taiichi Ohno
- defined 7 wastes - MUDA
- refined JIT with Kanban
- refined jidoka adding Andon
Shigeo Shingo
- developed SMED
- Poke Yoke - refined error proofing strategies
how to eliminate waste
in order to eliminate waste, you must set standards so that you know what your benchmarks for improvement are - must re-standardize continuously
TPS Lean House - most important aspect
- employee involvement
After Sales collapse, what did company agree to?
- lifetime employment
- wages tied to seniority
- wages tied to company profitability through bonuses
