What does Lean Manufacturing remove, and what does it add?
1) Removes waste from the system*
2) Adds value to a process
*without sacrificing productivity
What’s Lean Manufacturing’s rule of thumb?
Less of EVERYTHING
Eg. Less operator effort, less time, less storage space, less doing your mom, less materials, etc.
Who pioneered lean production, and at what university?
James P. Womack, MIT
What are the four measures of value?
1) Cost
2) Time
3) Quality
4) Flexibility
What are the three lean activities?
1) Value Added (Actual Work)
2) Non-Value Added (Indirect Work)
3) Waste
What type of lean activity is an oil change of a car?
Value Added Task
What type of lean activity is a group of mechanics meeting to talk about your car?
Non-Value Added Task
An activity that the customer does not pay for or need is called…
Waste
Also called “Muda”
What are the 8 types of wastes in lean?
1) Transport
2) Inventory
3) Motion
4) Waiting
5) Over-production
6) Over-Processing
7) Defect
8) Skills
Abbreviated to TIM WOODS
Tasks requiring excessive movement of inputs refers to…
Transportation
True or False: Transporting product between processes adds value to the product.
False
It provides no value between processes.
Excessive movement and handling creates opportunities for quality to _____________.
Deteriorate
True or False: Inventory gives a false sense of accomplishment.
True
Inventory Waste leads to an increase of what two elements?
1) Increased Lead Time
2) Waste of Floor Space
Inventory Waste is usually due to two contributing factors, what are they?
Bad Planning, Scheduling
What is Motion Waste defined as?
Any excessive movement of people
Eg. ‘Searching’ for products, unnecessary travelling of staff
What are the three contributing factors for motion waste?
1) Irregular Scheduling
2) Disorganized Work Environment
3) Inconsistent Information
What is Waiting Waste defined as?
By Idle Time, good not moving/being processed
What are the three drawbacks for waiting?
1) Higher Labor Cost
2) Wasted Energy
3) Lost Opportunity for Production
In terms of “Waiting” waste…
What are the three contributing factors?
1) Poor Accountability
2) Insensitive Scheduling Systems
3) Poor Staffing
What is over-processing waste defined as?
Using more expensive resources than necessary, adding features that are unnecessary
What are two contributing factors to over-processing?
1) Unlinked Systems
2) Lack of Systems
How are over-processing and over-production connected?
Resources are expensive –> Overproduce to recover resource cost
What is the definition of overproduction?
Manufacture an item before it is actually required.
