Lecture 4: Principles of lean & lean tools (value & waste) Flashcards
In which areas is lean manufacturing eliminating waste? (4)
- customer relations
- product design
- supplier networks
- factory management
Which 4 things does lean manufacturing want to achieve?
- less human effort
- less inventory
- less time to develop products
- less space to become highly responsive to customer demand while producing top-quality products in the most efficient and economical manner possible.
What is the core goal of lean manufacturing?
reduce lead time by reducing waste
What are 4 other goals of lean manufacturing?
- improving quality
- reducing costs
- improving morale
- improving safety
What are the benefits of lean manufacturing? (5)
- increase in unit sales volume
- less customer rejects
- on-time delivery
- lot size
- better manufacturing lead time
Who is the pioneer of Lean?
Toyota
What are the focus areas of Lean? (4)
- remove non-value-added steps to reduce cycle time and improve quality
- align production with demand
- reduce inventory
- improve morale, process safety and efficiency
Who developed Six Sigma?
Motorola
What is the focus area of six sigma?
Improving quality by controlling variation
What is Lean Six Sigma?
A combination of two powerful and proven process improvement methods Lean and Six Sigma builds on existing organization capability in quality, statistics, and project execution
As which 6 things can Six Sigma be defined?
- A measure of process
- Set up of tools
- Disciplined methodology
- Vision for quality
- Philosophy
- Strategy
What are the 5 lean principles?
- Specify VALUE from the standpoint of the customer
- Identify VALUE STREAM for each product and remove waste activities
- Make value FLOW towards the customer as quickly as possible
- Only at the PULL of the customer
- Strive for EXCELLENCE
Which 3 categories should the activities on the process map be divided into?
- Customer Value Added
- Business Value Added
- Non-Value Added
What are typical Customer Value Add activities (5)
- Assembly
- Service Delivery
- Call responding
- Fabricating
- Printing
What are typical Business Value Add activities? (5)
- Order entry/processing
- Purchasing
- Sales/marketing
- Regulatory Reporting
- Internal financial reporting
What are typical Non-Value Add activities? (7)
- Handling
- Inspecting
- Transporting
- Stocking
- Rework Loops
- Signoffs
- Delays
What are 3 questions you ask yourself in relation to Customer Value Add?
- Does the task transform the product or service?
- Is that transformation meaningful to the customer?
- Would the customer be willing to pay?
What are 4 questions you ask yourself in relation to Business Value Add?
- Does this task reduce the financial risk?
- Does this task support financial reporting requirements?
- Would the process break down if this task were removed?
- Is this task required by law or regulation?
What are 3 questions you ask yourself in relation to Non-Value Add?
- If the customer knew we were doing this, would they want to pay less?
- Does the task fit into the other 2 categories?
- Can I reduce this activity?
What is a KANO analysis?
A quality measurement tool used to prioritize customer requirements based on their impact on customer satisfaction
What is a KANO analysis used to determine?
To determine which requirements are important
What are the 4 types of customer needs?
- The ‘surprise and delight’ factors. These really make your product stand out from others
- The ‘more is better’
- The ‘must be’ things. Without this, you’ll never sell the product
- ‘Dissatisfiers’, the things that cause your customers to not like the product
What are 7 things in which you can identify waste?
- Inventory
- Overproduction
- Material movement
- Overprocessing
- Motion
- Correction
- Waiting
What is waste when talking about inventory?
any supply in excess of one-piece flow
What is waste when talking about overproduction?
producing more or sooner than the customer needs
What is waste when talking about material movement?
moving material not needed for ‘just-in-time’ production
What is waste when talking about overprocessing?
extra efforts that add no customer value to the product
What is waste when talking about motion?
Any movement that adds no value
What is waste when talking about correction?
failing driven activities: inspection, rework, testing, scrao
What is waste when talking about waiting?
being idle between operations
What 3 things do you have to think about at Toyota while improving quality?
- Use less time
- Use less space
- Use less resources
Which 3 things is lean?
Fast
Flexible
Flow
What does TPS stand for?
Total Production System
On which 2 concepts is TPS based?
Jidoka and Just in Time Principle
What is Jidoka?
Automation with a human touch
What does Jidoka do?
When a problem occurs, the equipment stops immediately preventing defective products from being produced
Via what are problems communicated when making use of Jidoka?
Andon or problem communication board
What does JIT stand for
Just in time principle
What do you do when you apply the JIT principle?
each process produces only what is needed by the next process in a continuous flow. You make only what is needed when it is needed, in the amount needed
What is another name for the JIT principle
stockless production
What is the Kanban system?
A Japanese system that is developed to support the logistics production chain. In the warehouse, it is ideally suited to make inventory management more efficient and to identify bottlenecks. This is done by means of visual representation
Who developed the Kanban System?
Taiichi Ohno of Toyota
What is the goal of the JIT principle?
to minimize the presence of non-value-adding operations and non-moving inventories in the production line
