Lean and Flexible Manufacturing Concepts

These flashcards cover key terms and definitions related to lean manufacturing and flexible manufacturing, focusing on their definitions, main features, and pros and cons.

Lean Manufacturing

A systematic approach to minimising waste within a manufacturing system without sacrificing productivity.

Flexible and responsive manufacturing

Manufacturing that focuses on the ability to quickly adapt to changes in product design, demand, or production volume.

Continuous Improvement (Kaizen)

An ongoing effort to improve products, services, or processes.

Just-in-Time (JIT) Inventory

An inventory strategy that aims to reduce waste by receiving goods only as they are needed in the production process.

Defects

Errors or flaws in products or processes that lead to customer dissatisfaction.

Overproduction

Producing more items than needed or before they are needed, leading to excess inventory and increased costs.

Waiting

The time spent by workers, equipment, or processes not being productive, leading to delays in the production process.

Non-utilized potential

The unused capabilities of employees, equipment, or processes that could improve production efficiency and effectiveness.

Transport

The movement of materials or products between different locations in the production process, which can add time and waste if not optimized.

Inventory

The raw materials, work-in-progress, or finished goods that are held in stock at any point in the production process, which can lead to unnecessary costs if not managed efficiently.

Motion

The movement of people or equipment within a production process, which can contribute to inefficiencies and waste if excessive or poorly managed.

Extra processing

Refers to unnecessary steps or procedures in the production process that do not add value to the final product, leading to waste and inefficiency.

Main Aim of Lean Manufacturing

To maximise customer value while using fewer resources.

Pros of Lean Manufacturing

Reduces costs, improves quality, enhances workflow efficiency, promotes continuous improvement.

Cons of Lean Manufacturing

Can require significant investment, may cause over-reliance on suppliers, less effective with variable demand.

Modular Production Processes

Production systems that are designed to be adaptable and capable of handling small batch sizes.

Main Features of Flexible and responsive manufacturing

Ability to handle small batch sizes, rapid reconfiguration of machinery, integration of advanced technologies.

Pros of Flexible and responsive manufacturing

High adaptability, supports a diverse product range, shortens product lifecycle times, facilitates innovation in design and manufacturing

Cons of Flexible and responsive manufacturing

High implementation costs, requires skilled workforce, potential downtime during changes.