Lecture 10 Flashcards
What is the primary objective of Lean manufacturing?
Lean manufacturing aims to reduce waste (like waiting time, inventory, defects, and delays) without sacrificing value delivered to customers.
Where and when was Lean manufacturing developed?
Lean manufacturing was developed in Toyota plants in Japan in the 1950s, gaining recognition in the late 20th century.
What are some key elements of Lean manufacturing?
Key elements include high volume, customer value, people involvement, continuous improvement, Just-in-Time (JIT), and waste reduction.
What is Just-in-Time (JIT) manufacturing?
JIT is a manufacturing philosophy that aims to produce the required item at the required quality, quantity, and time, reducing waste and encouraging continuous improvement.
What is the difference between Just-in-Time (JIT) and traditional manufacturing practices?
JIT minimizes inventories and produces only what is needed, while traditional practices use large inventories to buffer against production issues.
What are the main requirements for Just-in-Time (JIT) manufacturing to work effectively?
Stable production schedules, small batch sizes, on-time delivery, defect-free components, reliable equipment, capable workforce, and pull manufacturing.
How does a pull system differ from a push system in manufacturing?
In a pull system, downstream stations order items only as needed from upstream stations, while in a push system, work moves from upstream to downstream stations regardless of immediate demand.
What is the Kanban system in JIT manufacturing?
Kanban is a system using production and transport cards to authorize production and workflow, ensuring items are only produced when needed by downstream stations.
List the main goals of JIT manufacturing.
Zero defects, zero setup time, zero inventories, zero lead time, zero part handling, zero breakdowns, and lot size of one.
How does JIT view setup times and batch sizes?
JIT aims to reduce setup times to near zero, allowing for minimal batch sizes, ideally leading to a batch size of one.
What are some types of waste that JIT manufacturing seeks to eliminate?
Overproduction, waiting, transportation delays, large inventories, overprocessing, and defects.
Why does inventory “hide” production problems in traditional manufacturing?
Excess inventory masks issues like quality problems, machine breakdowns, and supplier delays by providing a buffer instead of addressing root causes.
What are the three phases in transitioning to Lean production?
Phase 1: Essential implementations, Phase 2: Revision and training, Phase 3: Continuous improvement.
