Quality & Lean Operations

Question 1

Lean Operations Def and Goals

Answer 1

A concept that aims to reduce costs by eliminating all forms of waste (= Muda)

Just in time = eliminate inventories!

Goal:

• improved flexibility
• reduced lead times
• better quality
• reduction in costs

Question 2

Seven types of waste

Answer 2

• Inventory (excess)
• Overproduction
• Waiting
• Motion (excess)
• Transportation handling
• Processing (w/out added value)
• Defect correction

Question 3

Eliminate inventory

Answer 3

• Inventory hides problems
• lower inventory increases problem visibility
• Puts company voluntarily in a risk position
• need to eliminate all problem causes!

Question 4

Implementing a pull system to reduce overproduction:

Kanban

Answer 4

• Waiting line is strictly limited
• Each workstation is controlled by the short-term requirements of the downstream flow!
• Number of Kanban cards determines WIP level

Question 5

Eliminate waiting

Answer 5

• Reduce batch sizes!
• Mixed-model production: Heijunka

Question 6

Eliminate unnecessary transportation

Answer 6

• Layout re-eingineering
  
  • product routings: requires high capacity, machine reliability
  • Cell organization: multiskilled workers, autonomy

Question 7

Eliminate unnecessary processing

Answer 7

Map the processes and identify value-adding and non-value-adding steps!

Question 8

Three quality control principles

Answer 8

• Poka-Yoke: fool proof design
• Jidoka: Inspection at the source
• Andon: Line-stopping empowerment