Component 1-12. lean production

What is lean production?

Its aims to remove all elements of waste from the production process and as a result increase productivity and reduce costs. It focuses on maximising output with a minimum input in order to improve productivity.

What is Kaizen?

It is a Japanese word meaning continuous improvement. This takes the view that one of the main objectives of their existence is to continuously make small increment steps in the improvement of quality design and waste reduction.

In order for cars into work effectively, they must have what elements

A trained work force to be able to fix problems quickly without wasting time, security in their jobs so no employee will feel redundant which will keep motivation high, understanding the production process so managers can be organised control and plan so workers can try and meet their needs and quality requirements of consumers and a motivated workforce

What are benefits and problems with Kaizen?

Benefits.

Increase productivity, increase quality, reduction and waste, improved motivation of workforce, increased competitiveness, reduced disruption and labour unrest, less need for large scale investments.

Problems.

High training costs, slow to set up, may be a productivity dip when making changes to work out involvement

What is an example of eliminating waste?

It is an important part of Kaisen and could be time wasted while employees wait for materials or role materials being used in efficiently

What is just in time (JIT)?

It's aims to ensure that parts, raw materials and components are received only when there is a demand for the parts and demand for the products

Advantages and disadvantages of just in time

Advantages

Decrease costs, efficient, quality increase, can improve cash flow.

Disadvantages.

If supply is late production is shut down, there's a risk, demand can change quickly meaning they won't meet it, there is no backup supply if things go wrong

What is cell production?

The production line is subdivided into a number of cells. These cells are called groups of workers involved in related tasks

what are benefits and problems of cell production?

Benefits.

Increase productivity, unit cost decrease, teamwork means more motivation, absenteeism is decreased.

Problems.

Manager salaries decrease, some factories may have to close in big chains, self production may not allow a firm to use its machinery as intensively as in traditional flow productions

What is time base management?

It involves concept such as just in time the use of CAD and CAM and emphasis is placed on reducing time in all aspects of the whole production process

Advantages of time based management

Quicker response times to meet changing market and customer needs, faster new product development, reduction in waste therefore greater efficiency