Lean production

• What does lean production aim to achieve?

  Reduction and removal of waste
• How does lean production increase productivity?

  By removing elements of waste from production
• What are the key components of an effective lean production system?

  • Just-in-time
  • Kaizen
  • Cell production
  • Time-based management methods
• What are the benefits of lean production?

  • Increased productivity
  • Reduced costs
  • No stock holding with JIT
  • Fewer defective products
  • Shorter lead times
  • Improved reliability
  • Faster new product design
  • Reduced waste
• What does Just-in-Time (JIT) ensure?

  Parts and products are made on demand
• What is a key principle of JIT?

  If it isn’t wanted, don’t order it
• What are the advantages of Just-in-Time (JIT)?

  • Improves cash flow
  • Reduces waste
  • Frees up factory space
  • Lowers stock holding costs
  • Enhances supplier control
  • Boosts employee motivation
• What are the disadvantages of Just-in-Time (JIT)?

  • Depends on supplier reliability
  • Higher ordering costs
  • Loses bulk buying advantages
  • Hard to manage demand spikes
  • Risk of damaged reputation
  • Increased staff pressure
  • Supply interruptions
• What is cell production?

  Production line subdivided into cells
• What is a benefit of job rotation in cell production?

  Improves quality and flexibility
• How does cell production improve communication?

  By grouping workers involved in related tasks
• What is the focus of time-based management?

  Reducing time in the production process
• What concepts are involved in time-based management?

  • Just-in-time
  • Computer-aided design (CAD)
  • Computer-aided manufacture (CAM)
  • Critical path analysis
  • Simultaneous engineering
• What is the main objective of kaizen?

  Continuous improvement in processes
• What are kaizen groups?

  Groups of employees discussing improvements
• What are the key elements of kaizen?

  • Continuous improvement mindset
  • Recognition of technology's role
  • Motivated workforce
  • Management belief in workforce
  • Trained workforce
  • Effective communication systems
  • Job security for employees
  • Management understanding of processes
• What are the benefits of kaizen?

  • Improved labor relations
  • Enhanced quality
  • Increased productivity
  • Better motivation
  • Greater competitiveness
  • Waste reduction
  • Less need for large-scale investment
• What does the kaizen philosophy emphasize?

  Small incremental improvements
• How does kaizen affect costs?

  Reduces costs over time
• How does kaizen contribute to competitiveness?

  By improving quality and reducing waste
• What is the formula for continuous improvement in kaizen?

  Small Change + Small Change = Continuous Improvement
• What is the role of management in kaizen?

  To understand and support production processes
• Why is job security important in kaizen?

  It encourages employees to suggest improvements