Term
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Definition
| the belief that waste can be eliminated by cutting excess inventory and capacity and by removing non-value adding activities in operations |
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Term
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Definition
o Overproduction- manufacturing and item before its needed, making it difficult to detect defects and creating excessive lead times
o Inappropriate processing- using high tech, expensive machines when less high tech machines would suffice. It leads to over utilization of capital
o Waiting- waste of time when product is not being moved or processed
o Transportation- excessive movement or material handling without adding any value
o Motion- unnecessary effort related to bending, stretching, lifting etc.
o Inventory- excessive inventory hides problems, takes up space, increases lead time, and inhibits communication
o Defects- result in scrap and rework which consumes resources and adds waste
o Underutilization of employees- failure of a firm to capitalize on employees abilities and knowledge |
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Term
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Definition
| idea of continuous improvement |
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Term
| Elements of continuous improvement |
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Definition
| • Maintaining low inventories, periodically stressing the system to identify problems, and focusing on the elements of the lean system |
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Term
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Definition
| positive relations with suppliers to ensure quality, decrease lead time, and reliable scheduling |
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Term
| First step in developing a lean system |
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Definition
| cutting down suppliers and making sure they are located geographically close |
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Term
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Definition
| a quantity of items that is processed together |
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Term
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Definition
| low levels of inventory and defects have a smaller effect on small lots |
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Term
| disadvantages of small lots |
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Definition
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Term
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Definition
| having setup times of less than 10 minutes |
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Term
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Definition
| consumer demand activates production |
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Term
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Definition
| a method where production is activated before consumer need |
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Term
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Definition
| meshes the push and pull methods by making standardized units via the push method and assembling based on consumer need |
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Term
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Definition
| quality is monitored at the source where the defect is created |
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Term
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Definition
| the concept of automatically stopping the line when there is an issue or a defect |
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Term
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Definition
| mistake proofing methods aimed at designing fail safe processes the minimize human error |
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Term
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Definition
| a system the give machines and machine operators to signal the occurrence of any abnormalities (ie alarms, blinking lights, and LCD text displays) |
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Term
| When does a lean system work best? |
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Definition
| When the load at each workstation is uniform |
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Term
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Definition
| cycle time needed to match the rate of production to the rate of sales and consumption |
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Term
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Definition
| the leveling of production load by both volume and production mix (the same amount and mix are being produced each day) |
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Term
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Definition
| produces a mix of models in smaller lots |
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Term
| result of standardization of products |
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Definition
| increases the total quantity that must be produced while also increasing productivity and decreasing inventory |
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Term
| benefits of a flexible workforce |
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Definition
| allows for workers to be moved around to help relieve the bottleneck and decrease the need for inventory buffers |
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Term
| key to low cost operations |
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Definition
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Term
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Definition
| sort, straighten, shine, standardize, sustain |
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Term
| Total Preventative Maintenance (TPM) |
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Definition
| reduces the amount of machine downtime by replacing machine parts in routine maintenance instead of only fixing problems when they arise |
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Term
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Definition
| that balances the cost of preventative maintenance against the risk and cost of machine failure |
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Term
| Why line flows are recommended |
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Definition
| they reduce the need for frequent setups |
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Term
| One worker multiple machine (OWMM) |
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Definition
| a one person cell is designed so one worker operates multiple machines to achieve a line flow (a U shape is common) |
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Term
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Definition
| inventory and labor requirements because materials move automatically to the next step |
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Term
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Definition
| an option for achieving line flow with low volume processes; this creates cells that are not limited to one worker and has a unique way of selecting work to be done by the cell |
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Term
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Definition
| a qualitative tool used in lean systems for eliminating waste (muda) that involves a current state and future state drawing and an implementation plan |
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Term
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Definition
| the use of cards to control the flow of production through a factory |
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Term
| Operating rules for the Kanban system |
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Definition
o Each container must have a card
o The assembly line always withdrawals from the fabrication cell. The fabrication cell never pushes parts to the assembly line.
o Containers of parts must never be removed without a kanban first being posted
o The containers should always contain an equal number of good parts
o Only non-defective parts should make their way to the assembly line
o Total production should not exceed the total number of authorized kanbans |
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Term
| Determinations of managers in a Kanban system |
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Definition
o The number of units to be held by each container
o The number of containers flowing back and forth between the supplier and user stations |
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Term
| Key to finding the number of cards |
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Definition
| finding the average lead time |
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Term
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Definition
| a function of the processing time per container, the waiting time during the process, and the time required for the material handling |
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Term
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Definition
| the idea that the average WIP equals the average demand rate multiplied by the average time a unit spends in the manufacturing process, can be used to determine the number of containers |
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Term
| How are product mix and inventory managed in a Kanban system? |
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Definition
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Term
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Definition
| kanban system where a specific location or container for a unique part replaces the need for cards |
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Term
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Definition
| system where painted squares are used as the location for different items, and the number of squares is used to balance the line flow |
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Term
| To achieve full lean potential |
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Definition
o Schedule stability- stable schedules are needed so line production can be balanced
o Setups- setup times must be small to accommodate small batches
o Purchasing and logistics- deliveries must be reliable due to the low inventory levels of a lean system |
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