Lecture 9 Flashcards
Japanese Waste categories
- Muda - activities add no value
- Mura - Lack of consistence or balance
- Muri - unreasonable demands to process
Lean management meaning
systematic approach to optimizing efficiency by minimizing waste and maximizing value for the customer
Difference between lean flow and traditional flow
There is a inventory buffer for traditional flow between manufacturing stages while lean manufactures on request and does not stop between stages
Different views of capacity utilisation, lean vs traditional
Traditional has high inventory thus problems are not exposed thus have more stoppages. Lean has less stoppages because problems are exposed due to low inventory and on request manufacturing.
What is a typical tool to reduce Muri waste and how does it work
Takt time - the rate at which you need to complete a product or service to satisfy customer demand
Formula: the time to produce parts / the number of parts demanded in that time interval
Muda 7 types of waste
TIMWOOD
1. Transportation
2. Inventory
3. Motion
4. Waiting
5. Over-processing
6. Over-production
7. Defects
Ways to reduce waste
- Improve process layout - (e.g. seating of related fields workers)
- Improve process flexibility (reduce set-up time, use simpler machinery)
- Minimising variability (less batches, deliver small quantities more often)
Andon Cord (Stopping the line) concept meaning
system which notifies managerial, maintenance, and other workers of a quality or process problem
Gemba Walks (go-see) concept meaning
walkthrough which aims to observe employees, ask about their tasks, and identify productivity gains
Tackling Mura Muri and Muda with 5S
- Sort (Seiri) - Seperate needed and non-needed items
- Straighten (Seiton) - Position items for easy access
- Shine (Seiso) - Tidy up aesthetically [paint etc]
- Standardise (Seiketsu) - Maintain neatness as a daily routine
- Sustain (Shitsuke) - Audits
Kanban system
Leaving a signal card when something needs to be reordered
Pull vs Push system
Pull - responding to demand (Action on request)
Push - Calculated planning of future forcasted demand
Lean vs MRP (Manufactuting Resource Planning)
Lean:
-Pull system
-It is a philosophy rather than achievable
-Good on control, but weak on planning
MRP:
-Push system
-A planning and control calculating mechanism
- Strong on planning, weak on control and response to disturbance
-Good at dealing with complexity
Theory of constraints vs Lean
The system has 1 goal and several constraints. Bottleneck is the most restraining factor, focus on improving constrains.
While lean improves all processes continuously
