OM-Chapter 11 Flashcards
Lean management
Lean manufacturing
-Changing environment:lean philosophy
-Systematic approach required
-Used in tandem with other methodologies
-Just in time
-Toyota production system
-Elimination of waste
-Improved processes ,quality, productivity,inventory levels and employee participation
The methodology of lean production
Impacts throughout the organization
Advantages
-combining craft and mass production
-better choice of products
-improved efficiency ,quality and response
Positives gained
-Participation of employees
-Job enlargement and cross training
Prerequisites for lean system
-Specify content, sequence and timing of the tasks and the outcome desired
-Specify internal and external customer connections in the areas of number of employees, manufacturing method and timing of production
-Process flows uncomplicated and follow shortest route through process
-Improvements of a scientific nature and implemented at lowest possible level
Lean objectives
-Sustainable profit over long term by
-High quality standard for products
-Competitive production cost
-Manufacturing contain element of service
-Product mix competitive
Strategies, tactics and measures to achieve lean status
-Mission to eliminate waste
-Value-not simply applicable to manufacturing
-Lean journey-implementing
-Total production maintenance (TPM)
-Total quality management (TQM)
-Just in time (JIT)
Penetration strategy
-Training of employees
-Improvement projects
-Residence experts
The seven most common wastes
1.Waiting time waste
2.Transportation waste
3.Process waste
4.Inventory waste
5.Unnecessary motion waste
6.Product defect waste
7.Overproduction waste
Costs incurred as a result of waste
-Carrying cost
-Ordering cost
-Shortage cost
-Actual purchasing cost
-Idleness costs
-Semi-obvious costs
-Hidden costs
Kaizen vs Kanban
Kaizen: Is a systematic approach that includes all operations within the organization and aims to improve the quality of products and components that are delivered to customers
Kanban: Means visible record or signal and is a communication system used to enable customers to indicate when and in what quantities they require their materials to be replenished
Steps to achieving lean status
-Determine value
-Identify value stream
-Focus on customer by implementing lean production system
-Customer pull and not org push/force
-Pursue zero defects/perfection
Work design characteristics
-The variety of skills
-Clearly identified tasks
-Communicate importance and significance of each task
-Define ad communicate extend of employee autonomy
-Timeously and regular feedback of tasks completed
Lean manufacturer characteristics
1.Applying JIT methodology
2.Eliminate/minimise travelling distances of products
3.Develop close relationships with suppliers
4.Eliminate activities not adding value must be eliminated
5.Devolution of responsibilities to lower levels
Lean techniques
-Standard times
-Kaizen
-Matching demand and production
-Standardization
-Involvement of employees
5s methodology
JIT vs Lean vs TPS
-JIT places the emphasis on continuous improvement
-Lean production emphasises the need of an organisation to understand the customer
-TPS places the emphasis on employee empowerment as well as employee learning
