Lean Production
Define Lean Production.
A focus on eliminating as much waste as possible form a production system.
The value-adding and non-value adding activities required to design, order, and provide a product or service.
What is a Value Stream?
What are the 5 "lean" areas of a supply chain?
Lean Suppliers, Lean Procurement, Lean Warehousing, Lean Logistics, and Lean Customers.
Name the 2 areas of emphasis for Toyota Product System.
What is Elimination of Waste and Respect for People?
Group technology, quality at the source and JIT production are a part of _____________ .
What are lean layouts?
A system that promotes not producing any item until the customer has taken a unit from the retailer.
What is Pull System?
The optimization of the value-adding activities and the elimination of non-value-adding activities.
What is Waste Reduction?
In a lean supply chain _____________ are able to respond to changes; provide lower prices; and higher quality.
What are lean suppliers?
Identify how many categories of waste are identified in the Toyota Production System.
What is 7?
When designing for lean supply chains, production schedules are preferred to be inconsistent each and every day. (T/F)
What is False?
Give an example of a pull system.
Window from Lowe's. (1) A sale pulls the window from the shelf (2) This triggers a replacement order from the factory (3) Replacement order triggers the order of materials to produce new window.
Name one of the uncertainties in service operations presented in Chapter 7.
What is uncertainty in task times or demand or customers' production roles?
In lean warehousing, moving a unit to storage one day and then removing it from storage the next so more value adding steps could take place is considered lean. T/F
False.
When conducting continuous improvement events, when cost reductions involve fewer people on the production line, rather than firing people, the organization should allow employees to leave at their own pace - also known as _____________.
What is attrition?
In designing a lean supply chain, suppliers and customers are kept at arms length to promote better negotiation. (T/F)
What is False?
T/F. A pull system's foundation is that nothing will be produced until it is needed.
What is True?
T/F. Utilizing a framework to look across the supply chain and identify opportunities is critical.
What is True?
Lean ________ , in part, includes optimizing routes, effective cross docking, and minimizing backhaul.
What is lean logistics?
Name two of the 5 identifiers of Respect for People.
1. Lifetime employment for permanent positions.
2. Maintain level payrolls even when business conditions deteriorate.
3. Company unions.
4. Bonuses.
5. View workers as assets.
A type of maintenance emphasized in lean to keep manufacturing plants equipment running consistently.
What is preventive maintenance?
Lean Production includes 6 areas of focus. Name two of them.
1. High-volume production
2. Elimination of waste in the production effort.
3. Just-in-time production
4. Value chain focus
5. Customer value focus
6. Waste - elimination of non-value adding activities from the customer perspective.
An an activity which promotes the analysis of value added to the process and the identification of "waste" activities.
What is Value Stream Mapping?
Lean ____________ value speed and flexibility.
What are lean customers?
Name the 7 wastes of manufacturing.
1. Waste from overproduction.
2. Waste of waiting time.
3. Transportation waste.
4. Inventory waste.
5. Processing waste.
6. Waste of motion.
7. Waste from product defects.
The lean concept which promotes doing it right the first time and if something goes wrong, stop the process immediately.
What is quality at the source?