Chapter 68, Lean Production

Question 1

Lean Production

Answer 1

originated in Japan where all employees are involved in putting into operation a series of working practices that will help the business meet the demands of the consumer efficiently

Question 2

Different aspects of lean production

Answer 2

• Stock levels JIT
• Jidoka to reduce rejects
• Productivity reducing unit costs
• TQM
• Reduction in storage space needed
• Kaizen
• quality circles
• Time-based competition
• Ergonomics
• Cell Production
• Lead time for design

Question 3

Time-based Competition

Answer 3

attempt to reduce the time taken between generating ideas and it going into production

Question 4

Total Quality Managment TQM

Answer 4

considers the efficient use of all resources used in the production. all employees are responsible for the well being of the business. Finding ways to prevent mistakes rather than inspect them

Question 5

Jidoka

Answer 5

gives the ability to detect and reject faulty goods as early as possible. Uses Andon Light system using green amber and red

Question 6

Kaizen

Answer 6

‘continuous improvement’

Question 7

Quality and Quality Circles

Answer 7

employees between 4 and 10 in numbers are allowed to meet during working hours to discuss problems and pass on these suggestions on to management.

Question 8

Just-in-Time

Answer 8

levels of stock are kept low in order to reduce the amount of space needed to store stock
Kanban: helps organise the flow of components onto the production line at the right place and the right time.

Question 9

Benefits of JIT

Answer 9

• reduced costs due to less held stock
• less cash tied up in stock
• less likelihood of damages

Question 10

Risks of JIT

Answer 10

• any delay form supplier can be damaging
• any serious errors
• substantial set up cost with JIT

Question 11

Cell Production

Answer 11

a form of teamwork where employees are placed on different teams responsible for a particular part of the production.

Question 12

Ergonomics

Answer 12

looks at the relationship between employees and the capital equipment (machinary)