What is a Push System?
Also called “Just-In-Case” system
A system which releases materials/items/servcies into the process as projected customer orders are processed
What is a Pull System?
Also called “Just-In-Time” system
A system which releases materials/items/servcies into the process once the customer demands it
What are the 2 criterias of Lean Manufacturing?
- What the customer wants
- When the customer wants
What are 6 properties of Push System?
- Higher Inventories
- High Waste
- Anticipate the Need
- Production Approximation
- Poor Communication
- Made to Stock
What are 6 properties of Pull System?
- Lower Inventories
- Low Waste
- Actual Need/Demand
- Production Precision
- Better Communication
- Made to Order
What are the benefits of a Pull System?
HINT: There are 2 answers
- Factory operates only when it has to
- Time can be spent on other processes
Other processes include: Quality improvements, Team Meetings/Housekeeping, Worker training, Continuous improvement, The Production Process, Cost and Logistics, Transportation, Economics, Level Scheduling, Supplier Logistics & Supplier/Customer/Warehouse Floorspace
What is the 5S Methodology?
A process to make a work environment more efficient, productive and safer
Where is the 5S Methodology?
Lean Manufacturing/Enterprises
What are the 5 Steps of 5S Methodology?
- Sort (Seiri)
- Set (Seiton)
- Shine (Seiso)
- Standardize (Seiketsu)
- Sustain (Shitsuke)
Why is the 5S Methodology used?
To make sure workers are safe and perform their tasks effeciently
What do you do in the Sort step?
Decide what items are needed and not needed
This step: eliminates waste of inventory, reduces clutter, makes finding tools/supllies eaiser, reduces wasted motion & frees up wasted space
In the Sort step…
What are the 3 piles you should sort your items into?
- Keep
- Maybe
- Waste
What is the Red Tag technique?
A system where you place “Red Tags” on “uncessary items” for later reevaluation
What do you do in the Set step?
Arrange items (from the “Keep” pile) so that they are easy to find, use and/or return
This step: reduces excessive motion, reduces “searching”, makes missing items obvious, reduces space needed
During the Set step…
For Low Priority items, where should you palce them (relative to your work place)?
HINT: There are 2 answers
Low Priority items = items used once or less per year
- Throw away
- Store away from workplace
During the Set step…
For Medium Priority items, where should you palce them (relative to your work place)?
Medium Priority items = items used either once per month or once per week
Store together but offline
During the Set step…
For High Priority items, where should you palce them (relative to your work place)?
High Priority items = items used once per day
Locate at the workplace
What do you do in the Shine step?
Clean the workspace and make it look better than before
In this step, workers: clean, paint, dust, polish, shine, divde the workplace into zones, and anything else to make the environment more aesthically pleasing
What do you do in the Standardize step?
Create consistent procedures to maintain the first three S’s
In this step, the following occurs: tool standardizing, quicker tool changovers, photo aids are used to guide the worker, training is simplified, tool sharing becomes more optimal
What do you do in the Sustain step?
Ensure long-term adoption of the other 4 S’s
Training, audits, check-ins, and improvement are used to ensure this “S”
This step is important because it: saves money and increases worker morale
What is the Litmus Test for the 5 S’s?
A worker must locate a specific item withtin 30 seconds
Define Root Cause
A condition(s) that allows/causes a defect to occur
When properly corrected, the defect is eliminated permanently -> This provides long term relief
What is Root Cause Analysis?
A quantitative/qualitative approach that identifies root cause
What is the 5 Why’s approach?
An approach that forces management to reword the problem statement in order to idenitfy the source of the problem
Basically keep asking the manager “Why?” until you get to the root problem
