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what is lean production?
aims to eliminate waste and maximise the value of a product based on the perspective of the consumer
advantages of lean production?
increased productivity because of focus on continuous improvement and waste reduction
increased quality of product because of focus on improvement and reduction of defects
cost reduction because manufacturer is able to pass on cost savings to the consumer
increased profits through cost reduction and increased customer satisfaction
improved working conditions for employees
competitive advantage because of focus on cost reduction and productivity
reduced environmental impact due to reduction of waste of materials and resources
disadvantages of lean production?
high capital costs due to the need to invest in JIT systems and IT systems
difficult to introduce to existing workforce as some workers and managers may resist the change in manufacturing approach
dependant on a highly integrated system - if there was a breakdown in communication, deliveries, or production, the whole manufacturing system can come to a halt
no inventory can make it difficult to respond to sudden increases in demand or create a buffer in case of a production slowdown
characteristics of lean production?
JIT supplies/system
highly trained, multi-skilled workforce
zero inventory
zero defects
quality control and continuous improvement
what are JIT supplies/system (characteristics of lean production)?
the correct amount of material and parts delivered at the right time to eliminate inventory
what is zero inventory (characteristics of lean production)?
manufactured products are shipped immediately, avoiding the need for managing inventory
what are zero defects (characteristics of lean production)?
avoid defects by ensuring that no substandard materials and production practices are used
what is quality and control and continuous improvement (characteristics of lean production)?
an active approach to improvement
quality control and checks happen at all stages of the production
principles of lean production?
minimising inventory
elimination of all waste
designing for rapid production changeover
pulling production from customer demand
partnering with suppliers
doing it right the first time
maximising production flow
empowering workers
focus on kaizen
meeting customer requirements
why minimising inventory (principles of lean production)?
to reduce inventory management costs
why elimination of all waste (principles of lean production)?
wasted time
wasted material
reduction of errors and defects
why designing for rapid production changeover (principles of lean production)?
to allow for efficient retooling and changes in production goals
why pulling production from customer demand (principles of lean production)?
a JIT system is used to drive production rather than a JIC system
why partnering with suppliers (principles of lean production)?
to operate a successful and efficient JIT system
why doing it right the first time (principles of lean production)?
emphasises quality and reduces waste
why maximising production flow (principles of lean production)?
to take advantage of economies of scale
why empowering workers (principles of lean production)?
as they are the most valuable resource in the company
why focus on kaizen (principles of lean production)?
a philosophy of continuous improvement by all involved
why meeting customer requirements (principles of lean production)?
taking every single customer complaint and opinion of the product or service seriously
the flexibility of the lean production system determines the degree to which a company can meet individual customers needs
what is value stream mapping?
concerned with the big picture of the production process
the goal is to identify areas for improvement, optimising the overall process
a lean production management tool used to analyse current and future processes to produce a product through to delivery to the consumer
what is workflow analysis?
concerned with the details of the production line
considered the sequence, tools and even worker movement to ensure the highest possible efficiency in the system
what is a product family?
a group of products that have common components or elements
share common parts, manufacturing processes and architecture
advantages of product family?
reduced manufacturing costs, products use similar parts, techniques, suppliers
reduced R&D costs, changes are typically incremental and follow the ‘architecture of the design’
no need to design a product from scratch
attract a random of consumers, each product in the family can be targeted to the customers varying needs
easily adapt to the changes in market demand
waste is reduced, waste from one product can be used to manufacture parts for another
what is Kaizen?
a philosophy of continual improvement
has played a significant role in the success of many Japanese companies
for example, Toyota
emphasises the workforce as the most valuable component of a manufacturing system
founded on the belief that no system is perfect, and those in the system (the workers) are best placed to suggest improvements
training a skilled workforce develops an intimate understanding for the production process and empowers workers to identify areas for improvement
such an approach empowers employees across all levels, such systems are more horizontal and hierarchical
what are the 5 S’s?
a method for organising the workspace with the goal of improving the efficiency of production
what are the titles of the 5 S’s?
sort
set in order
shine
standardise
sustain
what is sort (5 S’s)?
keep just the necessary items in the workplace
why is sort beneficial (5 S’s)?
reduced time looking for items
reduce distractions
increase safety
simplify inspection
what is set in order (5 S’s)?
organise workplaces or workstations to optimise efficiency
why is set in order beneficial (5 S’s)?
increase efficiency of work flow
move finished items on quickly
labelled locations for tools and materials
what is standardise (5 S’s)?
set standards for a consistently organised workspace
why is standardise beneficial (5 S’s)?
ensure each worker knows what their responsibilities are
what is sustain (5 S’s)?
maintain and review standards continuously
why is sustain beneficial (5 S’s)?
perform regular audits, allowing time to review and improve
8 wastes in lean manufacturing?
defects
overproduction
waiting
unused talent
transportation
inventory
motion
extra-processing
what is defects (8 wastes in lean manufacturing)?
waste from a product or service failure to meet customer expectations
what is overproduction (8 wastes in lean manufacturing)?
waste from making more product than customers demand
what is waiting (8 wastes in lean manufacturing)?
waste from time spent waiting for the next process step to occur
what is unused talent (8 wastes in lean manufacturing)?
wastes due to underutilisation of people’s talents, skills, and knowledge
what is transportation (8 wastes in lean manufacturing)?
wasted time, resources, and costs when unnecessarily moving products and materials
what is inventory (8 wastes in lean manufacturing)?
wastes resulting from excess products and materials that aren’t processed
what is motion (8 wastes in lean manufacturing)?
wasted time and effort related to unnecessary movements by people
what is extra-processing (8 wastes in lean manufacturing)?
wastes related to more work or higher quality than is required
