What is the definition of Lean?
Doing more work with fewer resources
What is Taiichi Ohno's structure of the Toyota Production System?
What are the 7 (8) forms of waste?
Taiichi Ohno’s seven forms of waste:
Transportation: Unnecessary handling of materials
Inventory: Excessive inventories
Motion: Unnecessary movement of people
Waiting: Workers waiting
Overproduction: Production of more parts than needed
Overprocessing: Unnecessary processing steps
Defects: Production of defective parts
Skill: Failure of making best use of workers*
Definition of JIT production.
Produces and delivers exactly the required number of each component to the
downstream operation in the manufacturing sequence just at the moment
when the component is needed.
What does JIT minimise?
1. Inventory
2. WIP
, 3. lead times
4. Space and money invested in WIP
What is the generic Pull System? What are the limitations?
pull the product from the system at the rate of customer demand.
- technical constraints means it may be necessary to push the product o a certain
point, identifying the push-pull decoupling point is key
What is Toyota's way of implementing a pull system in production control?
Kanban system
1. Production kanban - authorises upstream station to produce a batch of parts
2. Transport kanban - authorises transport of the parts to the downstream station
What is the objective of the SMED?
Single Minue Exchange of Dies - to reduce the average inventory level, batch
size must be reduced, to reduce the batch size, set up times must be reduced.
What is the 8 step process to reducing set up times?
1. Analyse the set-up process
2. Classify set up operations: waste (operations which do not add any value to
set up), internal set ups (operations that can only be performed while the
machine is shut down) external set ups (operations that can be performed
without shutting down the machine)
3. Eliminate waste
4. Convert as many of the internal set ups to external as possible
5. Improve internal set ups to reduce time: quick change tooling, standard base
plates, quick locate nd fit connections
Doing more work with fewer resources
What is Taiichi Ohno's structure of the Toyota Production System?
What are the 7 (8) forms of waste?
Taiichi Ohno’s seven forms of waste:
Transportation: Unnecessary handling of materials
Inventory: Excessive inventories
Motion: Unnecessary movement of people
Waiting: Workers waiting
Overproduction: Production of more parts than needed
Overprocessing: Unnecessary processing steps
Defects: Production of defective parts
Skill: Failure of making best use of workers*
Definition of JIT production.
Produces and delivers exactly the required number of each component to the
downstream operation in the manufacturing sequence just at the moment
when the component is needed.
What does JIT minimise?
1. Inventory
2. WIP
, 3. lead times
4. Space and money invested in WIP
What is the generic Pull System? What are the limitations?
pull the product from the system at the rate of customer demand.
- technical constraints means it may be necessary to push the product o a certain
point, identifying the push-pull decoupling point is key
What is Toyota's way of implementing a pull system in production control?
Kanban system
1. Production kanban - authorises upstream station to produce a batch of parts
2. Transport kanban - authorises transport of the parts to the downstream station
What is the objective of the SMED?
Single Minue Exchange of Dies - to reduce the average inventory level, batch
size must be reduced, to reduce the batch size, set up times must be reduced.
What is the 8 step process to reducing set up times?
1. Analyse the set-up process
2. Classify set up operations: waste (operations which do not add any value to
set up), internal set ups (operations that can only be performed while the
machine is shut down) external set ups (operations that can be performed
without shutting down the machine)
3. Eliminate waste
4. Convert as many of the internal set ups to external as possible
5. Improve internal set ups to reduce time: quick change tooling, standard base
plates, quick locate nd fit connections
