Lean Systems

Question 1

Lean Systems

Answer 1

operations systems maximize the value added by removing unnecessary activities & delays

Question 2

Just In Time

Answer 2

customer demand can be met while eliminating all forms of waste and non-value-added activities and continuously improving value-added activities.

Question 3

Muda and types (7)

Answer 3

Form of wast in JIT
o Overproduction
o Inappropriate processing
o Transportation
o Motion or Waiting
o Inventory
o Defects
o Under-utilization of employees

Question 4

Benefits of JIT (4)

Answer 4

• Shorter customer wait times
• Higher employee productivity
• Higher utilization rates
• Lower inventory cost

Question 5

Downsides of JIT

Answer 5

• Employee burnout, strain
• Lack of breaks or rest for employees

Question 6

Lean Supply Chain

Answer 6

Close Supplier Ties and Small Batch Sizes

Question 7

Close Supplier Ties (4)

Answer 7

• Low inventory levels mean frequent, small deliveries from suppliers
• Less tolerance for poor quality, late deliveries
• Shorter lead times = less safety stock
• Trust them to deliver, small frequent delivery

Question 8

Small Batch Ties

Answer 8

• Small batch sizes reduce cycle inventory
• Reducing cycle inventory decreases holding/manufacturing costs
• Support uniform loading across workstations

Question 9

Pull Method

Answer 9

production triggered by customer demand or order for products – Toyota Car Parts

Question 10

Push Method

Answer 10

production is started in advance of order etc anticipation for predictable demand – Fries

Question 11

Type of process and job using both push and pull

Answer 11

Assemble to Order - Subway

Question 12

Workforce Flexibility

Answer 12

workers can handle variety of tasks and shift workstations to alleviate bottlenecks

Question 13

Quality at the source

Answer 13

employees act as their own inspectors

Question 14

Poka-yoke

Answer 14

Mistake-proofing method to reduce human error

Question 15

Jidoke

Answer 15

Automation that prevents defects from moving forward in the production line

Question 16

Andon

Answer 16

A visual/auditory signal to communicate the need for help to resolve a problem

Question 17

Uniform Loading (2)

Answer 17

spread demand evenly across months and production system
Design your system so daily load on individual workstations and daily demand for resources is constant

Question 18

Takt Time

Answer 18

Cycle time of process needed to match the rate of production to the rate of sales or demand

Question 19

Heijunka:

Answer 19

Levelling of production by both volume and product mix

Question 20

Mixed-model assembly:

Answer 20

type of assembly that produces a mix of models in smaller batches

Question 21

Fives S’s:

Answer 21

Sort
Set In Order
Shine
Standardize
Sustain

Question 22

Sort

Answer 22

separate needed from unneeded items, discard everything that is unneeded

Question 23

Set In Order

Answer 23

arrange what is left, find place for everything and put in place

Question 24

Shine:

Answer 24

clean and wash work area to help make problems visible

Question 25

Standardize:

Answer 25

establish schedules and methods for the first 3 S’s to maintain cleanliness

Question 26

Sustain

Answer 26

create discipline and an organizational culture around the 5 S’s

Question 27

Work Cells:

Answer 27

Group of several different workstations located close to each other that process a limited number of parts, products or customer with similar process requirements