Lean Production Flashcards

Flashcards reviewing the key concepts of lean production, JIT, and Kaizen.

Lean Production (kaizen)

The idea of eliminating waste within a business to increase productivity and reduce costs.

Examples of waste in Lean Production

Raw materials lying around unused, work in progress sitting in parts bins, finished product sitting in a warehouse, and skills/knowledge of workers not being used.

Key components of an effective lean production system

Just-in-time, kaizen, cell production, and time-based management methods.

Benefits of Lean Production

Raised productivity, reduced costs, reduced defective products, cut lead times, improved reliability, quicker new product design, reduced waste.

Just-in-Time (JIT)

Ensuring parts, raw materials, and components are received and products are made only when there is demand.

Advantages of Just-in-Time

Improved cash flow, reduced waste, freed up factory space, reduced stock holding costs, improved supplier relationships, improved employee motivation.

Disadvantages of Just-in-Time

Reliance on supplier reliability and flexibility, potential increase in ordering costs, loss of bulk buying advantages, difficulty coping with demand spikes, potential damage to reputation due to late deliveries, increased staff pressure, unforeseen supply interruptions.

Cell Production

Subdividing the production line into cells, where groups of workers are involved in related tasks.

Characteristics of Cell Production

Employees are trained to fulfill multiple tasks, improving quality and flexibility; communication is improved; cells can be self-managing.

Time-Based Management

Regarding time as a key business resource and emphasizing speed of development, response, and delivery.

Kaizen (Continuous Improvement)

Continually making small incremental steps in the improvement of quality, design, and waste reduction.

Kaizen Groups

Groups of employees who meet regularly to discuss problems and suggest improvements within the production process.

Key Elements of Kaizen

Employee commitment to continuous improvement, management belief in workforce capabilities, a trained workforce, effective communication systems, job security, and management understanding of production processes.

Benefits of Kaizen

Improved labor relations, improved quality, increased productivity, improved motivation, increased competitiveness, reduction in waste, less large-scale investment.