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.