Lecture 2 Flashcards
What cultural and historical factors contributed to Lean production in Japan?
- Zaibatsu and Keiretsu models emphasizing supplier loyalty and vertical disintegration.
- Post-WWII industrial policies and challenges.
- Lifetime employment and strong supplier relationships.
What is the Toyota Production System (TPS), and what are its key principles?
TPS is a management system focused on eliminating waste and building quality. Key principles include:
- Just-in-Time (JIT): Producing only what is needed when it’s needed.
- Five Zeros: Zero delay, zero inventory, zero paper, zero defects, and zero breakdowns.
- Continuous improvement through a learning culture.
What are the five principles of Lean production?
- Define value from the customer’s perspective.
- Map the value stream and eliminate non-value-adding steps.
- Create flow by ensuring smooth production processes.
- Implement a pull system driven by real-time demand.
- Pursue perfection through continuous improvement.
How does Lean production compare with other production systems in terms of adaptability?
- Pure Fordism: Lean but rigid in adaptability.
- Recent Fordism: Buffered but rigid.
- Craftsmanship: Buffered and flexible.
- Toyota Production System (TPS): Lean and flexible.
How does Lean production impact the firm level?
Optimizes end-to-end value streams. Reduces waste, costs, and lead times while improving quality. Aligns operational practices with strategic goals.
How does Lean production affect individual employees?
Encourages multi-skilled employees in team-oriented environments. Promotes engagement in problem-solving and continuous improvement. May lead to concerns about job security due to efficiency gains.
What were the findings of Holweg’s (2007) article on the genealogy of Lean production?
Lean production evolved through iterative learning at Toyota. It combines Japanese and Western practices. Lean’s success stems from adaptability and its dynamic nature, making it applicable beyond Japan.
What did Womack and Jones (1994) propose about Lean production?
They extended Lean principles to the ‘Lean Enterprise,’ which integrates functions and organizations across the value stream. Identified resistance from traditional structures as a key barrier to adoption. Highlighted Lean enterprise as a systemic transformation beyond manufacturing.
What distinguishes Lean systems from buffered systems?
Lean systems focus on eliminating waste, continuous improvement, and flexibility. Buffered systems rely on inventory and excess capacity to handle uncertainties.
What is the significance of value stream mapping in Lean production?
It identifies and eliminates non-value-adding steps, ensuring efficient and value-driven processes.
