Lecture 8 Flashcards
Lean
maximizes customer value while minimizing waste (creates more value for customers with fewer resources)
whats the goal of Lean?
provide “perfect value” for the customer through a perfect value creation process with 0 waste
waste
anything your customer isn’t willing to pay extra for (aka nything more than the minimum amount of equipment, etc.)
5 principles of lean
- identify value
- map value stream
- create flow
- establish pull
- seek perfection
value stream
all the activities and rsources required to deliver product/service to customer (MEANS LOOKING AT BIG PICTURE, NOT JUST INDIVIDUAL PROCESSES)
how is lean a systematic approach?
it identifies and eliminates waste thru continous improvement (via flowing product at the pull of the customer)
cycle time / processing time
time when materials enter an operation to the point the finished product is produced
production lead time
total of all individual cycle times + waiting time b4 & after processing + setup/move time + non value added time
value added
any activity that increases the market form or function of the product or service (aka activities the customer is willing to pay for)
non value added
- any activity that does not add market form or function
- should be eliminated, simplified, reduced or integrated
DOWNTIME (aka waste categories)
- Defects
- Overproduction of WIP
- Waiting
- Non value added processing
- Transporation of materials & equipment
- Inventory Excesses
- Motion
- Employees underutilized
Examples of waste?
- watching a machine run
- waiting for parts
- counting parts
- making more than can be sold
- looking for tools
- machine breakdown
- storing work in process inventory
- rework
what does waste signal?
that time is trapped in the process
&
recognizing waste leads to identifying the root cause of problems
underlying waste is a systematic flaw in what?
the process involving people, materials, machines or information
whats standardized work?
repeatable and reliable operations
why standardize work?
- reduces general chaos
- new employees get up to speed faster
- easier to cross train
- provides foundation for improvement
5S
- ) Sort - eliminate clutter
- ) Set in Order - organize, label, set boundaries & limits
- ) Shine (or Scrub) - clean everything
- ) Standardize - set standard for every process
- ) Sustain - maintain discipline thru systems & supportive culture
why is a clean/organized/orderly workplace important?
provides a foundation for all other improvement activities
Lean methods for eliminating waste?
- Standardized Work
- Batch Reduction
- Teams
- 5S System
- Visual
- Plant layout
Visual Management
simple visual signals give employees the information to make the right decision
(common language for diverse workforce)
why consider changing physical layout?
- reduces the movement of people and materials
- supports better communication
POINT OF USE (POU)
instructions, raw materials, parts & tooling are stored at the workstation where they’re used
aka visual, small batch replenishment systems
-works best if vendor or material handling relationship permits frequent, on-time, small shipments
why do POU?
reduces wasteful sorting, moving, transporting parts * tooling
- identifies quality issues in a timely fashion
- simplifies inventory tracking, storage & handling
quality at the source
making it right the first time
inspection at the source
operators inspect product before passing it to the next workstation
why do quality at the source?
- eliminate or reduce final inspections
- increase throughput
- empower employees
- improve quality
- increase productivity
push system
-produces product using forecasts or schedule w/out regard for what is needed by the next operation
pull system
-method of controlling the flow of resources based on exactly what is needed by the next operation
supermarket system
buffer inventory used to control the production of an upstream process without scheduling
kanban cycle
- customer process withdraws what it needs
- kanban signal is released - visible demand
why use pull?
- flexible and simple method of balancing the flow resources
- effective way to communicate customer demand thru an operation
- more responsive to quality issues
cellular manufacturing
linking of manual and machine operations into the most efficient combo to maximize value added content while minimizing waste
GOAL - PRODUCE TO THE RATE OF DEMAND
when can cellular manufacturing be used?
wherever value added work can be performed continuously by passing the product, directly, one piece at a time, from work station to work station
value stream map
diagram that shows the flow of material, information and other resources as a product/service makes its way through the value stream
