Lecture 11: Performance improvement Flashcards
Name frameworks to assess operational improvement and excellence. (3)
BEF
Baldrige Excellence Framework
EFQM
European Foundation for Quality Management
Shingo
Prize for Operational Excellence
What are different types of production systems? (2)
Company-specific
production system
(customized Systems)
Off-the-shelf
production systems are
(available pre-built systems)
What are advantages and disadvantages of Off-the-Shelf Models? (4)
Advantages
- Cost-Effective
- Quicker Implementation
Disadvantages
- Lack of Customization
- Limited Scalability
What is the biggest challenges for the implementation of a company-specific production system (XPS)?
To sustain senior and middle management’s commitment
What are the two pillars of the Toyota Production System (TPS)?
- Just-in-Time (JIT): producing only what is needed, when it is needed
- Jidoka: refers to the ability of processes to detect abnormalities and automatically stop
Explain „Jidoka“!
Stop & fix the Problem
What means „Kaizen“?
“change for the better”
or
“continuous improvement.”
What are the five significant cultural aspects of the Toyota Way? (5)
- Continuous Improvement (Kaizen)
- Respect for People
- Teamwork and Collaboration
- Long-Term Thinking
- Genchi Genbutsu: “go and see for yourself“
What are the five principles of lean, also known as the Toyota Way principles? (5)
💰🏄♂️🚀
- Value: Specify customer value.
- Value Stream: Identify the value stream (product-process design, layout decision).
- Flow: Ensure a smooth and uninterrupted flow of work. Jidoka ans JIT are enemies oder Flow
- Pull: Implement a pull production.
- Continuous Improvement: Foster a culture of continuous improvement, also known as Kaizen.
What do you need to do to improve flow? (3)
Eliminate ..
- Muda: Waste, Inefficiency
- Mura: Unevenness, Variability
- Muri: Overburden, Strain
What does Muri, Mura and Muda mean?
- Muri – Overburden (Überlasten) (waste due to the poor design)
- Mura – Unevenness (imbalance due to poor implementation of the design)
- Muda – Waste
What are the seven wasters? Which one is the worst?
- Transportation
- Inventory
_ - Motion
- Waiting
_ - Overproduction
- Over-processing
_ - Defects
Name five methods and tools to
institutionalize improvement routines! (HIDDA)
H oshin Kanri (shared vision)
I mprovement Boards and Meetings (visual)
D aily Layered Accountability
D aily Kaizen Activities and Kaikaku Projects
A3 Management (problem solving)
What are the four steps of Jidoka?
- Discover abnormalities
- Stop the process
- Fix the problem
- Investigate and solve the root cause
What does Poka-Yoke? (2)
Mistake proofing, prevents defects by
- preventing,
- correcting,
- drawing attention to
human errors as they occur.
What are the 3 Poka Yoke mechanisms?
Contact
Method based on physical attributes (the product’s shape Kaikaku Projects .: O2 connectors)
Fixed-Value
Method based on number of movements (e.g. number of screws: Only 8 screws if you need 8 screws)
Motion-step
Method based on sequence of events (e.g. correct assembly order: Money after bank card removal)
Why is Poka Yoke important? (3)
- Eliminates mistakes
- Ensures that processes work right the first time
- Improves quality and reliability
What are the three guiding questions before implementing Poka Yoke?
- What is the cause of the defect?
- Is there an easy way to prevent the defect from occurring?
- In the event of a defect, how can it be detected and controlled?
What is 5S?
Workplace organization concepts
What do the 5s stand for? Explain!
Seiri = “Sort”
- Needed things.
- To sort things at your workplace by deciding what is actually needed
Seiton = “Set”
- Order things for time.
- Order things in the workplace to reduce time spent on non-value added activities searching for items, tools and documents
Seiso = “Shine”
- Clean.
- To clean the workplace.
Seiketsu = “Standardize”
- To maintain the first three pillars by creating a consistent approach to completing tasks.
Shitsuke = “Sustain”
- To maintain the previous 4S and make a habit of maintaining correct procedures.
What is 5S used for? (3)
Used to create an efficient and attractive workplace that:
- Eases communication
- Helps to focus kaizen
What does it result in (indirectly)? (3)
- Safety
- Quality
- Productivity
Name three problem solving methods!
- PDCA method (Plan-Do-Check-Act) or PDSA (Plan-Do-Study-Act)
- DMAIC model (Define, Measure, Analyze, Improve & Control)
- 8D-Problem Solving (“Eight Disciplines”)
What are the process phases for 8D vs PDCA & DMAIC problem-solving approaches?
