Process Improvements Flashcards
Origins of Lean Manufacturing stem from:
“Just in Time” Philosophy, with emphasis of reducing waste
in the supply chain.
The basis of lean manufacturing means producing:
What is needed, when it is needed, With the minimum amount of materials, equipment, labor, and space,
The goal of an enterprise adopting lean improvements:
Make each process as efficient and effective as
possible, and connecting those processes in a stream or continuous chain that is focused on flow and
maximizing customer value
Process/Manufacturing Flow is defined as:
continuous movement of products and information through a
value stream, minimizing idle and downtime.
What is a batch process?
The execution of a series of jobs without manual intervention (non-interactive). Push System
Completes a predetermined quantity of work from an established work queue or forecast. Typically, the
work queue or forecast is offset to the actual customer demand to allow time for production and
delivery. NO FLOW!
What are the arguments for batch processes?
High inventory, high degree of risk, great convenience for customers in a hurry
What is a Single-Piece Flow Process?
The execution of parts that are moved through operations from step-to-step with no Work in Progress in
between. Pull System Completes a quantity of work that is directly linked to customer demand with
materials that are staged at the point of consumption. As materials are consumed, signals (Kanban) are
sent to previous steps in the process to pull forward sufficient materials to replenish only those that have
been consumed. Helps achieve true just-in-time manufacturing.
Ultimately, selection of the model to be implemented should be dictated by marketplace demands
with the goal of maximizing customer value!
How do you provide Customer Value?
Determination of what is value-added is made from the customer’s perspective, what they buy, which
will lead to specific activities needed to add that value to the products. For an activity to be value-added
it must meet the following three criteria:
1. The customer must be willing to pay for the activity
2. The part or the object must change (movement, inspection)
3. It must be done right the first time
Under the philosophy of lean and continuous improvement, what are the two types of waste?
• Classified as required waste and pure waste
• Required waste represents activities that do not meet the three criteria for a value-added task but
are still necessary to support the creation of a product. Activities may be mandated by the
customer and/or government regulation (i.e. inspections/tests)
• Pure waste is associated with the idle time within a process, Pure waste activities represent the
top priority for elimination.
What are the seven sources of waste? (DOTWIMP)
Defects - Part failing functional test
- Part feature violating drawing dimensions
Over-production - Machining parts with no usage requirement
Transportation - Moving parts from one machine to another
Waiting - Partially machined parts on the shop floor queued for the next operation
Inventory - Completed parts that have not been purchased
Motion - Extra process steps
Processing - Part inspection
What is the 5S Methodology?
- Sort (seiri) means to clearly separate necessary items from the unnecessary. It requires the identification of what is needed to perform a particular operation or task and the removal of unneeded tools, equipment, files, parts, furniture, and so on, from the work area.
- Store (seiton) means to neatly arrange and create a place for each item for ease of use. It requires items to be organized based on the frequency of use. In addition, visual aids are employed to easily identify the needed items.
- Shine (seiso) means to perform daily cleaning and inspection of the equipment and work area.
- Standardize (seiketsu) means to determine, share, and use the best processes and methods. Standardization serves to minimize the variation and becomes the baseline for further improvement.
- Sustain (shitsuke) means to maintain the gains and to create a culture for future improvement. This element supports the philosophy of continuous improvement.
What are the five lean principles?
- Specify value in the eyes of the customer
- Identify the value stream and eliminate the waste
- Make value flow at the pull of the customer
- Involve and empower employees (there is no better source of insight than the employees who are
performing the work) - Continuously improve (kaizen) in pursuit of perfection
