SCM q3 Ch 8
Lean Layouts
are very visual (lines of visibility are unobstructed) with operators at one processing center able to monitor work at another.
SPC
as part of TQM efforts
Small batch scheduling
drives down costs by Reducing purchased, WIP, & finished goods inventories
Six Sigma
seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes
Kanban
signal card & part of JIT (pizza restaurant example)
Producer's risk
A buyer rejects a shipment of good quality units because the sample quality level did not meet standards.
Consumer's risk
Buyer accepts a shipment of poor-quality units because the sample falsely provides a positive answer.
Continuous Improvement (Kaizen)
Continuous approach to reduce process, delivery, & quality problems, such as machine breakdown problems, setup problems, & internal quality problems, This is a philosophy, think of the tortoise beats the hare over the long term.
DMAIC Improvement Cycle
Define, Measure, Analyze, Improve, Control
Lean Six Sigma
Describes the melding of lean production and Six Sigma quality practices, Input materials, WIP, and finished goods, Continuous Improvement (Kaizen)
Inventory & Setup Time Reduction
Excess inventory is waste, Reducing inventory levels causes production problems, Once problems are detected, they can be solved, The end result is a smoother running organization with less inventory investment.
Waste (Muda) Reduction
Firms reduce costs & add value by eliminating waste from the process.
Lean Supply Chain
JIT purchasing includes delivering smaller quantities, at right time, delivered to the right location, in the right quantities.
Workforce Commitment
Managers must support Lean Production by providing subordinates with the skills, tools, time, & other necessary resources to identify problems & implement solutions.
Key concepts incorporated in TPS
Muda, Kanban, SPC, Poka-Yoke
Six Sigma Quality
Near quality perfection (the statistical likelihood of non-defects 99.99966% of the time),
Six Sigma
Pioneered by Motorola in 1987, A statistics-based decision-making framework designed to make significant quality improvements in value-adding processes
Flow Diagrams
Process Maps, Annotated boxes representing process to show the process flow of products or customers.
Manufacturing cells
Process similar parts or components saving duplication of equipment & labor, often U-shaped
The Elements of Just-in-Time
Waste Reduction, Lean Supply Chain Relationships, Lean Layouts, Inventory & Setup Time Reduction, Small Batch Scheduling, Continuous Improvement, Workforce Empowerment
Acceptance Sampling
When shipments are received from suppliers, samples are taken & measured against the quality acceptance standard. The entire shipment is assumed to have the same quality as the sample.
Six Sigma Training Levels
Yellow, Green, Black, Master Black
Lean Production
an operating philosophy of waste reduction & value enhancement.
Small production batches
are accomplished with the use of kanbans. (who's been to a Brazilian restaurant?)
Waste (Muda)
encompasses wait times, inventories, material & people movement, processing steps, variability, any other non-value-adding activity.
Poka-Yoke
error or mistake-proofing (Dryer plug vs table lamp plug)
Pareto Charts
for presenting data in an organized fashion, indicating process problems from most to least severe.
Kanbans
generate demand for parts at all stages of production creating a "pull" system.
Lean Production
operating philosophy of waste reduction & value enhancement & was originally created as Toyota Production System (TPS)
Check Sheets
to determine frequencies for specific problems.
Cause-and-Effect Diagrams (Fishbone or Ishikawa diagrams)
used to aid in brainstorming & isolating the causes of a problem.
Statistical Process Control
visually monitor process performance, compare the performance to desired levels or standards take corrective action
Muda
waste in all aspects of production
