lean production- operations

Question 1

what is lean production

Answer 1

lean production is an approach to managment that focuses on minimise / cutting out waste in the production process, while ensuring quality

• which is any process that does not add value to a priduct

increasing productivity decreasing costs

Question 2

types of waste

Answer 2

• finished goods sat in the warehouse
• overproduction- making more than needed
• transport- moving resources around unnecisarily
• stocks- having an excessive buffrt
• skilled workers not working
• raw materials, sat in warehouse not beign used
• material that is damaged and cant be used - defects- doesnt reach required standard
• excess of raw materials

Question 3

what is just in time production

Answer 3

just in time production aims to reduce waste - when finished goods/ raw materials are not being added value to, this is minimised when orders are only made when there is demand for them

raw materials/ components made into products only when there is demand for them

pull system customers determine whats produced

Question 4

what is requaired to ensure a succesful JIT production

Answer 4

• good relationship with high quality suppliers, must have sufficient communication with suppliers to be able to ensure components are delivered when neccisary, may require setting up electronic systems such as EPOS to connect sales to suppliers
• workers / managers need to be appropriately trained and know how the JIT system works - be able to incorporate it
• beneficial if suppliers are close in proximity and flexible for EPOS to be succesful

Question 5

advantages of JIT

Answer 5

• ensures no waste- no working capital is tied up in stock/ finished goods- more working capital improving liquidity
• saves storacge space, rent and insurance costs- holding lower stock
• less liklehood of stock perishing and going obsolete
• ensure have correct stock neccisary
• reduces costs for business
• little to no mistakes are made as there is a mindset of getting it right the first time- increased efficiency

Question 6

disadvantages of JIT

Answer 6

• rely heavily on supplier, if deliverys are not met on time can lead to customer dissatisfied
• not alot of room for mistakes as dont have excess rae materials therefore if mistake is made could lead to delays
• unexpected orders cant be met as theres no spare finished product
• EPOS can be expensive

Question 7

what is kazien production

Answer 7

kazien is based on implimenting small incremental changes to a business to improve quality and efficiency
instead of large capital investments.

continous improvment

less likely for rmployees to resist as not making huge changes, easier to impliment

Question 8

what is the process of kazian production

Answer 8

employees focus on how and look for ways they can improve their work/ performance and thinking of ways to help the business

should take ownership of their work- help reinforce team working and increase motivation

workforce should be highly motivated, trained and efficient and committed to the business

should be effective communication systems allowing employees to…
communicate suggestions to superiors and other relevant employees

business can impliment changes in the short term to improve productivity and efficiency minimising the need to spend on large capital investment

although… doesnt ignore the need for new tech/ large scale capital investment but focuses on the idea that its not the only method of achieving increasing competitivness

Question 9

how is kazian implimented

Answer 9

use focus groups with a member of core departments which come together to discuss wasy in which businesses can improve their work, that can be made at minimal cost, increase quality and productivity

Question 10

advnategs of kazien

Answer 10

• avoids large costs of capital investment but allows competitive advnatages through small chnages at minimla cost
• workforce motivated as they feel as if they have a objective to work towards and better themselves
• high morale as all working to achieve same goal
• increases quality and productivity
• reduced absenteeism and labour turnover

Question 11

disadvnatages of kazien

Answer 11

• slow process no immediate benefits so may fall behind in the short term
• some may find that constant change is stressful and high pressure to constantly improve- resistance
• costs of contriniously training and changeing business ethic/ enviro, time consuming
• might lead to businesses overlooking major tech advancments which are neccisary in some cases

-relies heavilty on leadership commitment if management arent supporting this approach employees may not fully engage in the kazien approach

Question 12

what is cell production

Answer 12

cell production is when the production process is split up into stages where employees focus on their stage

Question 13

adantages of cell production

Answer 13

• increased productivity
• increased quality as specialise in this cell
• increased motivation - team work, responsible for production of their cell
• good communication

Question 14

disadvantages of cell production

Answer 14

• may increase costs as more capital machinery could be required
• may be quicker on a production line, more intensive
• small scale production may be better off with production line as this increases ineffiencecies as they may not produce on a large enpugh scale
• high training costs initially
• if one cell produces quicker than another can lead to inefficencies, for example if onecell underperforms can disrupt whole production line
• need to be multi skilled, requires continous training high costs
• requires more space, higher rent
• may cause relationships to become damaged if disagree- decreased motivation and productivity

Question 15

what is time based managment

Answer 15

seeks to reduce time, considered a waste, in production process

speed adds value

• speed of development, delivery, production are important
• may use systems to reduce time in all aspects of production to delivery e.g. tech, CAD, CAM, critical path analysis, JIT, similtanous engineering

Question 16

what are the requirments for time based managment

Answer 16

flexoble production methods able to chnage quickly to different production volumes

• trained employees multi skilled, good communication between workers and managers reduce any ineffienciencies that could arise due to miscommunication

Question 17

advantages of time based management

Answer 17

able to quickly repond to chnaging conusmer wants and trends

reducing waste increasing effieciency and productivity

reducing costs and increasing profit margins

improved customer satusfaction, quciker delivery

Question 18

what is simitaneous engineering

Answer 18

helps with project managment , developing and launching new peoducts quicker

emphasis on carrying out production processes at same time/ near as possible e.g. designing, producing, marketing

reduce lead times

reduce time takes to reach market as product life cycles becoming shorter dont want to spend long time in development as trends change quickly

… must have effective communication between departments avoid wasting time and causing issues due to miscommunication

regular meetings

all involved in product development

work together completting activities in conjunction

Question 19

advantages of SE

Answer 19

• new products bought to market quick, one of the first do do so… able to charge premium price increasing profit margin

comp advanage as can establish brand loyalty before other businesses can

improved staff commitment

high quality

Improved Communication and Collaboration
Encourages cross-functional teamwork between departments (e.g. design, engineering, marketing)

cost savings