Lecture 8 - Lean management Flashcards
What is meant by a Lean system?
Operations systems that maximize the value added by each of a company’s activities by removing waste and delays from them.
What is the lean philosophy?
- Lean is a fit for new activities, lean is not just cutting out several tasks
• Lean is not only tools – it is end-to-end value stream
• Lean is waste prevention
• Lean is value – to the customer and the value stream
• Lean is system – it is more than the sum of the components (tools or workers alone)
• Lean is process – not in terms of optimising functions or departments but the overall value chain
• Lean is Revolution and Evolution – it is rejecting some practices while evolving new thoughts and practices
• Lean is distributed decisions – Centralised strategic decisions; however for operational decisions the Lean way is to deal on a localised level
• Lean is service – waste prevention + value adding to all
• Lean is build to order – there is no set toolbox! Lean needs to be
customised to your organisation.
What are Womacks 5 principles of lean management?
- Specify what creates value from the customers perspective
- Identify all steps across the whole value stream
- Make those actions that create value flow
- Only make what is pulled by the customer just-in-time
- Strive for perfection by continually removing successive layers of waste
What is meant by a “Pulled System”?
Pulled system - the demand dictates what we produce, not based on forecasts but rather based on real demand. No guess is made.
What is meant by the 8 types of Muda?
- Overproduction
- Inappropriate Processing
- Waiting
- Transportation
- Motion
- Inventory
- Defects
- Underutilization of Employees
- Try to not produce to much - only produce if there is a demand
- For each process we will look at that process complexity to make it simpler if possible
- Products that are waiting in front of machine = waste. Everything that waits, could be in the end of the transport line.
- Transportation is waste, in terms of transportation between machines in the company.
- A lot of stretching to process a product - should be simplified
- Products are just put on hold and waiting
- If quality is bad then we will have defects which is waste
- Employeers should be trained so that they can be utilized to the fullest
What are examples of metrics of value stream mapping?
• Takt Time
– Daily Availability/Daily Demand
• Cycle Time
• Setup Time
• Throughput time
• Capacity
– Availability/Time at bottleneckWhat are the 5 S’s of the Visual workplace agenda?
- Step 1 – Sort / Organization (seiri)
- Step 2 – Set in Order / Orderliness (seiton)
- Step 3 – Shine / Cleanliness (seiso)
- Step 4 – Standardize / Standardizing (seiketsu)
- Step 5 – Sustain / Discipline (shitsuke)
What is the difference between the Lean Management world and the Western world, in terms of “Zero defects”?
- Lean: Looking to causes and try to solve them as quickly as possible
- Western world: Have severeal inspection point problems
What is meant by “Poka Yoke”?
Poka Yoke: Will find ways that a product can be finished in one way only in order for the product to be of great quality - by doing this quality is assured
What is meant by “Jidoka”?
Jidoka: stops the line and everybody in that workstation will come to try to solve that problem together. Not common in the western world.
What is meant by “Just-in-Time” systems?
produce and deliver finished goods just in time to be sold (etc)
What is meant by a “Push Method Workflow”?
A method in which production of the item begins in advance of customer needs.
What are 6 general operating rules?
- Each container must have a card.
- Assembly always withdraws from fabrication (pull system).
- Containers cannot be moved without a kanban.
- Containers should contain the same number of parts.
- Only good parts are passed along.
- Production should not exceed authorization.
What is meant by “Little’s Law”?
Average work-in-process inventory equals the average demand rate multiplied by the average time a unit spends in the manufacturing process
What are the 8 tools of Lean management?
- Process improvement through elimination of waste
- Zero Defect
- Pull instead of Push
- Multi-functional teams
- Decentralized responsibilities
- Vertical information systems
- Continuous improvement
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