lean production

• What does the term "lean production" refer to?

  Lean production refers to theories of modern Japanese industrial management aimed at reducing waste within a business.
• How is waste defined in lean production?

  Waste is any process that does not add value to a product.
• What are examples of waste in lean production?

  • Raw materials lying unused
  • Work in progress waiting to be used
  • Finished products waiting for delivery
  • Underutilized skills and knowledge of workers
• What is the primary goal of lean production?

  The primary goal of lean production is to remove waste from the production process to increase productivity and reduce costs.
• What business approach is necessary for effective lean production?

  • A complete change from traditional hierarchical structures
  • Adoption of a flexible, people-based structure
  • Implementation of complex systems
• What are the key components of an effective lean production system?

  • Just-in-time
  • Kaizen
  • Cell production
  • Time-based management methods
• What does just-in-time (JIT) production aim to achieve?

  Just-in-time production aims to ensure that parts and products are made only when there is demand for them.
• What is the first stage in incorporating a just-in-time program?

  The first stage is for managers to fully understand the production process by 'walking the line'.
• Why is it important for managers to understand the production process in JIT?

  Managers must understand the production process to effectively incorporate just-in-time practices.
• What is necessary for effective incorporation of just-in-time systems?

  Strong relationships with suppliers and effective communication systems are necessary.
• How do bar codes assist in just-in-time systems?

  Bar codes on work in progress automatically order stock from suppliers as products move along the production line.
• What is the Kanban system in just-in-time production?

  Kanban involves using order cards to ensure a regular and timely supply of components.
• Why is employee involvement crucial in just-in-time systems?

  Employee involvement is crucial because workers must be trained to use lean production systems effectively.
• What are the key elements of Kaizen?

  • Continuous improvement
  • Involvement of all employees
  • Motivation and belief in workforce capabilities
  • Effective communication systems
  • Security of jobs
• What does Kaizen mean?

  Kaizen is a Japanese word meaning continuous improvement.
• How did improvements in quality occur before Kaizen?

  Improvements were made in large one-off steps due to competitive pressure.
• What are the problems with the stepped approach to improvements?

  The stepped approach often leads to businesses playing 'catch-up' and can result in redundancies.
• What is the main working element of Kaizen?

  The main working element is the use of Kaizen groups that discuss problems and suggest improvements.
• What are the benefits of Kaizen?

  • Improved labour relations
  • Increased competitiveness
  • Reduction in waste
  • Less large-scale investment
  • Improved motivation
  • Increased productivity
  • Improved quality
• What is cell production?

  Cell production subdivides the production line into groups of workers involved in related tasks.
• What are the benefits of cell production?

  Cell production improves communication, job enrichment, and allows for job rotation among workers.
• What does time-based management emphasize?

  Time-based management emphasizes reducing time taken in all aspects of 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 simultaneous engineering?

  Simultaneous engineering involves carrying out design, production, and marketing functions as close to simultaneously as possible.
• What is necessary for effective simultaneous engineering?

  Effective communication between functional departments and regular product meetings are necessary.
• What are the discussion themes related to lean production?

  • Definition of lean production
  • Lean production practices at Dell
  • Explanation of 'waste' in lean production
  • Circumstances when JIT may not be the best method
  • Benefits of adopting lean production