lean production

Question 1

Methods of lean production

Answer 1

• kaizen
• JIT
• cell production
• time - based management

Question 2

Benefit of Kaizen

Answer 2

• reduced waste in the production process - increased productivity / reduced costs

Question 3

Drawbacks of Kaizen

Answer 3

• Staff may not wish to be involved in the process
• costs of setting it up

Question 4

Benefits of JIT

Answer 4

• lower stock holding - less storage space is required - rent / insurance costs are lowered
• less working capital is tied up in stock

Question 5

Drawbacks of JIT (4)

Answer 5

• mistakes in the production process - failure to meet customer orders
• process is heavily reliant on having excellent relations with suppliers
• can’t bulk buy
• large investment in computer software ( so suppliers know when they need material )

Question 6

Benefits of cell production (4)

Answer 6

• multi-skilling - job rotation - motivation
• multi-skilling - flexibility - meet the businesses future needs
• cell has responsibilities (completing work, covering absences and identifying recruitment and training needs) - job enrichment
• working in teams - improved communication

Question 7

Drawback of cell-production

Answer 7

• staff are constantly pushed for more and more output / improvements - demotivation - absenteeism

Question 8

Benefit of time-based management

Answer 8

• reduces lead times - quicker response to customer needs

Question 9

Drawback of time-based management

Answer 9

• can’t benefit from economies of scale ( only order sufficient materials )