Lean Tools and Techniques Flashcards
Compare and Contrast Continuous Improvement and Radical Change (Kaikaku)
Continuous Improvement (Kaizen) has been used as the principal improvement technique in Japanese companies for decades. Their belief is that it is usually easier to make a series of manageable small steps, rather than a single, great big, leap upwards.
Radical Change, or Kaikaku, is making quantum change for big and rapid results.
If it is an early improvement initiative then a team based Kaizen approach is preferable for areas such as workplace layout and housekeeping.
This gives a win/win result, with the workforce enjoying more pleasant conditions and the business efficiency improving.
Once people are on board with change and willing to support further improvements it makes sense to tackle one or more radical change projects, although these need to be more carefully selected and controlled.
Define Kaizen Improvements
Kaizen is means Continuous Improvement, using a series of small complementary improvements, and has proved successful in companies all over the world.
Describe the steps for implementing Kaizen Improvements
The most successful way to make Kaizen work is to involve all of the key members of the workforce, and to use a very structured technique for improvement project management, such as QOS.
The first step should be to identify areas where improvement will be most beneficial; next collect data to confirm the current situation.
Set up your Improvement Teams:
Each should be run by a Project Champion (probably by someone at supervisory level.),
Should have about six other members from different parts of the organisation,
Should be supported by a management sponsor, who must show support and help remove roadblocks.
Use the formal structure of the QOS process to guide each team through the improvement process, and then publish the results on a weekly basis.
What is 5S/CANDO in general terms
5S is a Japanese technique for setting up a clean, efficient workplace.
It benefits both the company and its employees, because it increases business efficiency, shortens lead times, improves workplace appearance and working conditions, and reduces the risk of accidents.
It can also generate immediate income from the sale of surplus equipment.
What are the 5S’s
Sort
Sorting out the working area so that anything that is not frequently required is cleared away, and anything which is no longer needed is sold or disposed of.
Set
Means arranging the items you do require for ease of use. This typically involves placing the correct tools exactly where they are needed, often on a shadow-board, which gives an immediate visual cue when something is missing. (can be 3rd process)
Shine
Means clean up. Having cleared the area, any spillage or leak become immediately apparent and can be tackled at source to keep the area clean. (This stage is often carried out before Set.)
Standardise
Means repeat the first three stages. Soon everything is in its own place, from pallets to tools, and clutter is made obvious and is quickly removed. Shadow Boards are often used to locate key items.
Sustain
Means continue using 5S.
What is CANDO the same as and what does it stand for?
5S
CANDO is an alternative acronym, representing:
Clean-up Arrange Neatness Discipline On-going improvement
What are the Seven Key Wastes? What are the two hidden wastes?
- Waiting
- Overproduction
- Rejects, defects, non-compliances
- Movement
- Over-processing
- Inventory
- Transport / Conveyance
In addition to these, there are two hidden wastes;-
- Failing to meet customer needs
- Unfulfilled human potential
Why are the Seven wastes key to Lean Manufacturing
The identification and elimination of waste (or muda as the Japanese call it) is one of the easiest ways to make a very significant impact on business process.
Outline a Technique for Set Up Improvement
- Timeframes
- Acronym
- Example Features
Most set-ups can be improved using Single Minute Exchange of Dies (SMED).
Shigeo Shingo, who was the guru of set up and change-over improvement, stated that no change-over need take more than 20 minutes, and that 10 minutes is a realistic target. When he made this claim to the big automotive press companies, their times were typically eighteen hours; they are now all in the 10-20 minute band.
SMED works by analyzing the whole process from start to finish in great detail, breaking each operation down into increments of a few seconds. The external components are identified and taken outside the process, and then attention is focused on shortening the remaining internal operations.
Typical features include using jigs to locate items in position quickly, incorporating conical dowels for accurate alignment, and replacing traditional fasteners with 90 degree locks.
What does Poka Yoke mean?
Poka Yoke effectively means Mistake-Proofing.
The utilization of poka-yoke firstly reduces the number of errors or rejects, by reducing the opportunities for variation or mistakes.
Secondly, it allows operators with lower skill levels to successfully take on more complex jobs.
Define Push Manufacturing?
Involves using a forecast to produce a production and purchasing plan, and then “pushing” the items through manufacture into a warehouse, for picking and distribution to customers.
What are the advantages and disadvantages of Push Manufacturing?
The disadvantages of this are that
• a large number of defective products may be made before anyone realizes that the goods are not suitable
• the true demand will differ from the forecast, resulting in shortages and slow-moving stock
• substantial amounts of capital are tied up in stock
• the business is very vulnerable if their customer stops ordering that product
• lead times for “customer specials” tend to be long, reducing in lost opportunities for high added-value work
The advantages are that
• a very stable production plan is possible
• large batches can be made, giving economies of scale
What is Pull Manufacturing?
Pull manufacture involves not making something until there is an actual customer order for that product, and then manufacturing the item efficiently in a very short time.
What is Single Piece Flow?
Single piece flow is regarded as the ultimate in pull manufacture, where batch sizes have been reduced to the point that orders can be made individually.
Why is Pull Manufacturing desirable?
It is particularly important that systems for rapid manufacture (eg SMED, supply-chain optimisation, poka-yoke, etc.) are in place before the change is made.
The reality is that nearly all businesses are more profitable when they adapt pull, and absolutely all give a better customer service in the medium to long term.
What is Benchmarking and why is it important?
Benchmarking is comparing your own performance, in a number of key areas, to that of the leaders in each area.
It reveals the areas where your business is ahead of others, so that you can make the most of those strengths. Additionally, it shows where other companies are ahead of yours, highlighting areas for improvement.
What is Internal Benchmarking?
Internal benchmarking within your own company, eg;- comparing one branch or shop to another, highlights differences and can be used to identify best internal standards so that all branches can move up to those.
What is Competitive Benchmarking?
In competitive benchmarking, as the name suggests, you compare your business to your competitors in the same market.
What is Process and Performance Benchmarking?
What makes companies World Class?
Process (eg;- recruitment or equipment maintenance) and performance (eg;- quality or customer hit rates) benchmarking are comparisons with companies in all businesses and in all locations.
Being the best in one of these areas is described as being World Class, but because other companies are constantly improving, you have to keep improving and to repeat the benchmarking process to make sure that you remain World Class!
What is 6 Sigma?
Six Sigma is a measure of how good a process is. The concept was developed principally by Motorola, who set a target of less than 3.4 defects per million opportunities. At the time this was regarded as a particularly ambitious target.
