types of lean production

Question 1

what is kaizen?

Answer 1

continuous improvement
constantly introducing small incremental changes in a business in order to improve quality and efficiency.

Question 2

where do the ideas for kaizen come from?

Answer 2

the employees

Question 3

What do the kaizen groups do?

Answer 3

brought together to identify potential improvements

as opposed to using R&D, consultants, equipment which are very expensive

Question 4

advantages of kaizen?

Answer 4

• Small changes less likely to require major capital investment
• Encourages employees to take ownership of their work → This can help to improve teamwork and motivation
• Will help the business to remain competitive → product quality may improve, leading to an increase in business reputation

Question 5

disadvantages of kaizen?

Answer 5

• Employees may be reluctant to make any suggestions on how to improve the production process as their jobs may become affected
• Also due to the procedure of continuous improvement employees may feel under pressure and stressed. However, without continuous improvement the business will become uncompetitive and jobs will be lost

Question 6

what is cell production?

Answer 6

A form of team working where production processes are split into cells. Each cell is responsible for a complete unit of work.

Question 7

advantages of cell production?

Answer 7

• Closeness of cell members → improve communication
• Workers can become multiskilled (adaptable to needs of the business)
• Greater employee motivation (variety of work, team working and responsibility) –> increased productivity
• Quality improvements as each cell has ownership

Question 8

disadvantages of cell production?

Answer 8

• Closeness of cell members could lead to disagreements
• Workers may not be interested in becoming multiskilled and want to specialise in one
• Employees may not want the responsibility of a variety of work or working within a team –> decreased motivation

Question 9

what is ergonomics

Answer 9

looks at the relationship between the employee and the capital equipment (machine or tool) being used.

Question 10

what is an effective ergonomic design?

Answer 10

a minimum amount of time is wasted in using the machine or equipment

Question 11

where is an effective ergonomic design seen?

you don’t need this card necessarily, it’s just good info :))

Answer 11

This is seen in many car plants where the tools are deliberately hung on spring coils so the worker can literally let them go once finished with them saving valuable seconds in not having to walk and place the tool back.

Question 12

advantages of ergonomics?

Answer 12

• Time based savings in using machines and equipment
• Employees may feel more motivated as equipment is available on hand when it is needed (no down time)
• if the process is carried out again and again by multiple employees cost savings will add up

Question 13

disadvantages of ergonomics?

Answer 13

• need to pay for the cost of ergonomic analysis and implementation
• Customisation for each employee may come at a cost
• Potential break down in ergonomic equipment may lead to increased down time

Question 14

what is total quality management? (TQM)

Answer 14

considers the efficient usage of all resources used with the production process, whether directly/indirectly related to the production process

All employees are responsible for the wellbeing of a business.

Question 15

advantages of TQM?

total quality management

Answer 15

• Employees may feel empowered ☞ increasing motivation
• Improves quality of the end product
• Increases customer loyalty

Question 16

disadvantages of TQM?

total quality management

Answer 16

• Workers may feel resistant to change ☞ demotivation

Question 17

what is time based management? (TBM)

Answer 17

recognises the importance of time and tries to reduce the level of wasted time in the production process

general approach

Question 18

how does production need to be for TBM?

time based management

Answer 18

flexible

Question 19

what does TBM need?

time based management

2

Answer 19

• calls for flexible, multi-skilled staff
• culture of mutual trust between workers and managers.

Question 20

advantages of TBM?

time based management

Answer 20

• Quicker response times (reduced lead times) to meet changing market and customer needs
• Faster new product development
• Reduction in waste, therefore greater efficiency

Question 21

disadvantages of TBM?

time based management

Answer 21

• Employees may feel under pressure to complete products on time ☞ stress and demotivation
• Employees may be resistant to change

Question 22

what is jidoka?

Answer 22

the ability to detect/reject faulty goods/components at the earliest possible moment in the production process

Question 23

what is downtime for?

Answer 23

If the production process has to stop ☞ can be very costly

Question 24

what is jidoka an aid for?

Answer 24

prevent defects occurring and keeps the production process moving

Question 25

what are andon lights?

Answer 25

Adon light signs are displayed alongside every line to enable management and supervisors to check the progress of each section of the assembly line
Red - bad
orange - okay
green - good

Question 26

advantages of jidoka?

Answer 26

• stops extra downtime = cost savings
• Different coloured lights allow management to determine the seriousness of the problem and problems can be prioritised

Question 27

disadvantages of jidoka?

Answer 27

Initially could disrupt production in the short term, However the benefits far outweigh this perceived disadvantage

Question 28

what is kanban - JIT?

Answer 28

KANBAN:
helps to organise the flow of components onto the production line at the right place at the right time

JIT:
levels of stock are kept low in order to reduce space needed to hold stock

Question 29

how does a kanban card work?

Answer 29

when the kanban card detects a shortage of stock:
Automatically, additional stock from the suppliers will arrive on time, just in time to be used on the line.

Question 30

when do inputs arrive?

Answer 30

• Inputs arrive as and when they are needed (orders determine what is produced)
• However needs close cooperation with suppliers and can become complex so specialist software may be need to connect production with suppliers.

Question 31

advantages of kanban (JIT)?

Answer 31

• Lower stock hold (reduces costs)
• Stock less likely to perish/obsolete
• Less time spent on checking/reworking because emphasis is on getting the work right first time

Question 32

disadvantages of kanban (JIT)?

Answer 32

• Little room for mistakes as little stock held
• High reliance on suppliers
• No spare finished product available to meet unexpected orders
• Need for complex stock systems

Question 33

what is the overall benefit of lean production?

Answer 33

business can become more cost effective and can remain competitve

Question 34

what does lean production assume?

Answer 34

full co-operation of all staff and the support of management.

Question 35

what is lean production?

Answer 35

an approach to management that focuses on cutting out waste, whilst ensuring quality and improving efficiency in the continuous process of improvement