Menlo Lean 101-103 Flashcards
Why change?
So that improvements will be a result of internal factors before it becomes a result of external factors
Name the five internal factors:
Strained Finances, Performance, Changes in leadership, Technology and Growth
Name the five external factors:
Economic Forces and Competition, Technology, Regulatory/Political, legal changes and Social
Name the three competitive risks for the future:
Market Conditions
Competitors
Increased Customer expectations
Give six ways how lean will benefit me:
Over-burdened workloads stop firefighting Effective meetings and teamwork Clearer objectives improved quality
What are the 7 processes for change:
Acknowledge the crisis Create a vision Create a partnership Create Commitment Leadership involvement Create s sense of urgency Drive Results
Name 5 Lean Strategic Lean House initiatives:
Sustain and advance lean globally Improve Cash Flow Develop Advanced Lean Leaders Reduce planned administrative Cost Improve Globalized STSU process
Name the 5 components of the Lean Vision:
Customer Culture Leadership Associates Process
Name the 5 levels of Lean maturity:
Awareness Basic Stabilization Growth Maturity
Name 4 reasons why we use Lean:
System is proven
It is for our success
It drives from the customers perspective
It promotes our long term vision
What is JIT?
Just In Time manufacutring
What is Jidoka?
Intelligent Automation with built in quality
Name the 4 steps of Jidoka:
Detect the error
STOP
Fix or correct the condition and
find the root cause and countermeasure
What year did Toyoda automate?
1926
What year did Toyota motor company form?
1930
When did Toyoda study Lean from Demming?
1950
What year was the NUMMI Formed?
1984
What does NUMMI stand for?
New United Motor Manufacturers Inc.
When did Toyota import its first car into the US?
1965
When was Lean production introduced to the world through “The Machine That Changed the World”?
1993
Who wrote the book “The Machine That Changed The World?
Massachus Institute of Technology MIT
When did Toyota become the most profitable Carmarker in the world?
2006
What is Lean?
Business philosophy of continuous improvement by deploying cross functional teams and small groups to discover, analyze and eliminate sources of waste by using standard Lean principles
What is VOC?
Voice of Customer
True or False Customer could be internal or external
True
What is Genchi Genbutsu?
Go Look, Go See
Name 6 characteristics of Continuous Improvement?
Improve the way we add value for the customer
waste discovery and elimination
Everyone takes ownership
using the tools, skills and authority to improve
Teams
Understanding it’s a journey
What is the continuous improvement philosophy?
There is always something that can be improved
What is the continuous improvement approach?
Proactive vs reactive
What is the continuous improvement idea?
start by managing and improving your own job
What does MUDA mean?
Waste
What does MURA mean?
Unevenness
What does MURI mean?
Overburdening
Name the 3 MU’s of waste:
MUDA, MURA, and MURI
Name 7 + 2 primary waste:
Inventory Overproducing Overprocessing Over engineering Motion Transport/Transfer Defect Unused employee creativity Waiting
Define Gemba:
It is the place where truth can be found
What method should be used? on a Go Look, Go See
5 Why Root Cause
What is the foundation of Lean?
Stability
What are the 4 M’s of Lean Stability?
Manpower
Method
Machine
Material
What is Value Stream?
all the activities a company must do to design, order, produce, deliver and service the customer
What is process?
a specific sequence
Name 4 mapping formats:
Process
Value Stream Map
Swim Lane Process Map
Spaghetti Diagram
Name 6 Value Stream Goals:
Reduce Lead-times Reduce Inventory and overall cost Improve Quality Identify Waste continuous improvement
Name the 2 type of Kaizen:
Flow
Process
What is process Kaizen?
Elimination of waste
What is Flow Kaizen?
Value Stream Improvement
What is VA?
Value Added or process time
What is NVA?
Non Value Added or wait time
What is NNVA?
Necessary Non Value Added
Define transport/transfer waste:
the unnecessary transportation of parts and/or information
Define waiting waste:
idle or not engaged in value added activity
Define inventory waste:
holding of excess product/information, materials or supplies
Define defect waste:
to work over again, to revise, to repeat a process in order to correct a error
Define overprocessing waste:
working beyond what is needed to satisfy the customer. unnecessary steps in processing
ex. customer requires one label, but process puts two labels
Define Motion waste:
movement of people or equipment that does not add value to the process
Define overproduction waste:
producing more than what is required to meet actual demand of the customer. Making a few extra just incase.
What is volume data?
Historical data over extended periods of time
What is performance data?
Actual operating performance information not projected or goal
What is customer data?
information that defines customer requirements
What is system data?
Information that clearly captures systems abilities and constraints
What is a S.M.A.R.T. target?
Specific, Measurable, Attainable, Relevant and Trackable
What is strategic tracking?
alignment of goals and objective across the organization
Fact based decisions require what:
Facts
Name 3 elements of catchball communications:
Open to key ideas from the customer
All stakeholders are involved
Sound structure for continuous improvement
What is the visual management triangle
We see together
We know together
We Act together
Give 4 things that visual management must be:
Big enough to see
easy to understand
Important
drive improvement
What does SQCDM mean?
Safety, Quality, Communications, Delivery, and Morale
What is 5S?
Discipline and control over daily activities
Name the 5S in order:
Sort Set In Order Shine Standardize Sustain
What is sort?
separating the necessary items from the unnecessary items
What is Set In Order?
arrange all items remaining after the sort in an orderly manner
What is Shine?
Clean equipment, tools, machines, desktop, walls, floors
What is standardize?
making cleaning and checking a routine
What is sustain?
Self discipline and commitment to keep doing the previous 4S’s
Sort usually begins with what?
Red Tag Campaign
How do you set up a email reference system?
Sort: Emails into Action or Reference
How do you Set In Order email?
4D’s Delete It, Do It, Delegate It, Designate time for it.
What is Heijunka?
Workload leveling
What are the 3 laws of Operational System:
Bad Systems defeat Good people
Local Heroes produce weaker Operational systems
We are all connected
Name 3 principles of Process Management
- Reliable results come from reliable processes
- Improved results come from improved processes
- Teamwork is mandatory
What is Kaizen?
Mind set of continuous improvement
Small consistent changes
Problem solving/process improvement method
What is the heart of Kaizen?
PDCA
Name the 7 steps of Kaizen:
Theme Grasp the situation develop a plan carryout a plan Check the plan Take Action Conclusions
Name 4 type of A3’s:
Problem Solving/Process Improvement
Information
Status
Proposal
Define continuous flow:
aligning materials, manpower, machinery and methods
What does Takt mean?
Tempo, Pace of meeting customer expectation
Failure to implement pull will result in what?
Too much inventory
Not enough Inventory
What produces only what the customer demands?
Pull Systems
What is built in quality?
doing the right thing the first time.
What is Poka-Yoke?
Avoiding Error
