terms
The practice of asking "why?" five times when a failure has occurred, in order to get the root cause of the problem
5 why's definition
the maximum output level a company can sustain to provide its products or services. Depending on the business type, capacity can refer to a production process, human resources allocation, or technical thresholds
Capacity
a management philosophy aimed at eliminating waste from every aspect of manufacturing and its related activities. The term JIT refers to producing only what is needed, when it is needed, in just the amount needed
Just in Time production
Poka yoke
production based production flow
groups different workstations together according to the products they work on.
have advantage of keeping specific production jobs relativley contained. This increases flow, reduces work in process, and shortens lead-times
Japanese for continuous improvement. A Kaizen event is when owners and operators of a process spend a focused amount of time to make improvements to that process by eliminating waste.
Kaizen
Three basic improvement techniques
combine, simplify, eliminate
maintains an orderly and efficient flow of materials throughout the entire manufacturing process with low inventory and work in process. A printed card that contains specific info.
Kanban
Preventive machine maintenance
a program to maintain equipment in optimum working condition to prevent any unplanned downtime due to breakdowns
pull production system
a production of pushing large lots of material through the system, based on a predetermined schedule or forecast.
an order, or part of an order, for goods or services that cannot be filled at the current time due to a lack of available supply. A high number of backorders indicates the production system is not adequately matching supply with demand.
Backorder
cost is the amount of money spent by the company in the manufacturing of a product. Value is the usefulness of any product to a customer
Cost/Value
when a problem occurs on a production line, a worker is able to stop the process and prevent defective goods from being produced.
Line stoppage
Process
a repeatable collection of related, structiured activities or tasks performed by people or equipment in which a specific sequence produces a particular outcome to achienve a business goal/
setup time
the time required to prepare a device, machine, process, or system to function or accept a job
a business capability is what a business does and can do. Capability denotes the "what" that a business can do, whereas a business process if how a particular activity gets done.
Capability
cost is the amount of money spent by the company in the manufacturing of a product. Value is the usefulness of any product to a customer
Efficiency
Mixed model production
producing a variety of different products on the same line, according to demand, without sacrificing productivity, space, inventory, quality, or manufacturing lead-time.
process based production flow
process based production groups workstations together according to the activities being performed, regardless of which products each workstation is working on.
standard operations
determining a single way to make product. this is done using the work methods, materials, tools, machinery settings and training
Benefits if the 5 whys
1. Easy to teach
2. easy to use
3. introduce people to problem solving method
4. prevents band aid solutions
Drawbacks of the 5 whys
1. not data driven, so not repeatable
2. biasing the results
3. limit personalized experience
4. does not account for multiple causes
5. relying exclusively on 5 ways
one piece flow
the concept of moving one workpiece at a time between operations within a workcell.
increase economies of scale, allowing individual processes to function more efficiently by pooling resources
u shaped cells
the cell operators finish their work in the same location they start in, eliminating the waste of walking from the end of the line back to the start.