E2: CHAPTER 7 (JIT & Lean)
Define "poka-yoke"
a type of visual signal that means "foolproof" and refers to devices or mechanisms that prevent defects from occurring.
The underlying premise of JIT is that ...
all waste can be eliminated
3. Respect for people
an element of JIT that considers human resources an essential part of the JIT philosophy
Variations of Kanban Production
1.
5 Step Strategy for Quality Improvement
1. define quality in terms of the customer 2. translate customer needs into measurable terms 3. measure quality on an ongoing basis 4. set improvement targets and deadlines 5. develop a systematic method for improvement
Two types of kanban cards
1. production and 2. withdrawal
Define pull system
a manufacturing system that only "pulls" what is needed into production
Define bottom-round management
a JIT style of management, that means consensus management by committees or teams
Define flexibility
a company that can quickly adapt to the changing needs of its customers
Define uniform plant loading
a constant production plan for a facility with a given planning horizon
2. Total Quality Management (TQM)
an integrated effort designed to improve quality performance at every level of the organization
Define waste
anything that does not add value
Define "jidoka"
authority given to workers to stop the production line if a quality problem is detected
Define production card
authorizes the production of material
Define withdrawal card
authorizes the withdrawal of material
The reason traditional systems produce large quantities of one product before producing another is...
because of high setup cost
Beliefs that help define JIT
broad view of operations, simplicity, continuous improvement, visibility, and flexibility
Define continous improvement
called kaizen by the Japanese - a philosophy of never ending improvement
Define external setup
can be performed while the machine is still running
Define setup cost
cost incurred when setting up equipment for a production run
Define just-in-time (JIT) philosophy
getting the right quality of good at the right place and at the right time.
According to the JIT manufacturing philosophy inventory...
hides a wide variety of problems such as machine breakdowns, poor vendors, poor design, poor quality etc.
JIT is often called a pull system because...
it relies on a coordination system that withdraws parts from a previous work center and moves them to the next. the system relies on "cards" to pull the needed products through the production system
Define broad view of JIT
lean systems or lean production - encompasses the entire organization
Define types of waste
material, energy, time, space, or human activity that does not contribute to the value of the product or service being produced
Define visibility
part of the JIT philosophy - waste must be seen and identified in order to be eliminated. when waste is hidden problems are created
Define push systems
push products through the production system by producing the amount that has been forecasted of future demand
Traditional manufacturing systems are...
push systems
Key to success of JIT Manufacturing
reducing setup costs
Define internal setup
requires the machine to be stopped in order to be performed
Define quality circles
small teams of employees that volunteer to solve quality problems
Kanban card
specifies the exact quantity of product that needs to be produced.
Define kanban
the "cards" used to pull the needed products through the production system and specifies what is needed
Define JIT system
the 3 elements are 1. just-in-time manufacturing (JIT), 2. total quality management (TQM), and 3. respect for people
Define small-lot production
the ability to produce small quantities of products, (a principal way go eliminating inventory and excess processing while increasing flexibility)
JIT considers people...
the company's most precious resource
1. Just-in-time manufacturing
the element of JIT that focuses on the production system to achieve value-added manufacturing
Small-lot production shortens...
the manufacturing lead time
There is no excess production in a pull system b/c...
the only products and quantities produced are those specified by the kanban
Define cell manufacturing
the placement of dissimilar machines and equipment together in order to produce a family of products with similar processing requirements
Define simplicity
the simpler a solution, the better. - JIT is built around this
Define multifunction workers
those whom are capable of performing more than 1 job
Define quality at the source
uncovering the root cause of a quality problem.
Define broad view of the organization
understanding that all employees are responsible for serving the customer and meeting company goals
JIT manufacturing views inventory as...
waste that needs to be eliminated.