| What are the distinctions between JIT, TPS, and Lean ops? | 1. JIT emphasized forced problem solving
2. TPS emphasizes employee learning an empowerment in an assembly line environment
3. Lean ops emphasize understanding the customer |
| Define Lean and provide an example | Lean is a team-based form of continuous improvement focused on identifying and eliminating waste. |
| What are the 3 characteristics of lean? | 1. Eliminate Waste
2. Remove Variability
3. Improve Throughput |
| What are Ohno's 7 wastes? | 1. Overproduction
2. Queues
3. Transportation
4. Inventory
5. Motion
6. Over Processing
7. Defective Products |
| Define Overproduction | Producing more than the customer orders or producing early |
| Define Queues (waste) | Idle time & storage |
| How is Transportation a a waste? | Moving materials between plants or between work centers, handling more than once. |
| What kind of Inventory is a waste? | Unnecessary materials (raw, WIP, finished, ops supplies) |
| How can motion be wasteful? | Movement of equipment or people that adds no value is waste |
| What is over processing (waste)? | work performed on the product that adds no value. |
| What kinds of Defective products are waste? | Returns, warranty claims, rework, scrap |
| What are the 5 S's? | 1. Sort / Segregate
2. Simplify / Straighten
3. Shine / Sweep
4. Standardize
5. Sustain / Self-discipline |
| What does it mean to Sort/Segregate? | When it doubt, throw it out. |
| What does it mean to Simplify / Straighten? | Keep your station organized and you'll find what you're looking for, |
| What does it mean to Shine/ Sweep? | Keep your station clean |
| Define Standardization | Remove variations through SOPs and checklists |
| Define Sustain/Self-dicipline | Review periodically to recognize efforts and sustain progress. Use visuals for communication. |
| What are the extra 2 S's in the 5s's? | Safety & Support and Maintenence |
| How does an office use the 5s? | A place for everything and everything in its place |
| How do retail stores use the 5S's? | Reduce misplaced items |
| In what ways can variability affect lean operations? | 1. In the production process
2. Maintenance
3.Unknown or changing customer demand
4. Incomplete specs |
| What 2 techniques can be used to identify variability? | JIT & inventory reduction |
| What is throughput? | Measure of what it takes to move an order from start to finish |
| What is a technique for increasing throughput? Give an example | A system
Pull system |
| What are the 3 goals of Lean Production? | 1. Elimination of disruptions
2. System Flexibility
3. Continuous Improvement |
| How do disruptions impact lean operations? Give 3 examples of disruptions | Disruptions upset the flow of products through the production system.
poor quality, equipment breakdowns, late deliveries. |
| Why is a flexible system important to lean operations? | A flexible system can handle a mix of products and changers to level of output while maintaining throughput speed and enables the system to meet changing demand. |
| What are the principles of Kaizen? | 1. Improvement should be done gradually and continuously
2. Everyone should be involved
3. You don't have to spend on tech and consultants
4. It can be applied anywhere
5. Learn by doing, use scientific thinking
6. Rely on direct observation and data collection |
