Exam (elaborations)
LEAN MANUFACTURING EXAM 1
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LEAN MANUFACTURING EXAM 1...
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World Class Manufacturing - ANSWER The purpose of any manufacturingenterprise is to consistently make a profit, pure and simple. Being world-class in
manufacturing means that the company can compete successfully and make a
profit in an environment of international competition, not only now, but also in
the future.
Characteristics of World Class Manufacturing - ANSWER I.
Management/Employee Involvement
II. Focus on Quality
III. Efficient Production Operations
IV. Customer Focus
Qualifiers - ANSWER Those criteria that a company must meet for a customer
to even consider it as a possible supplier
Order-Winners - ANSWER Those criteria that win the order
Checking Markets - ANSWER Step 1. Define corporate objectives.
Step 2. Determine marketing strategies to meet these objectives.
Step 3. Assess how different products qualify in their respective markets and
win orders against competitors.
Step 4. Establish the most appropriate process to manufacture these products.
Step 5. Provide the manufacturing infrastructure to support production.
Agile Manufacturing - ANSWER The integration of organization, highly
skilled, knowledgeable and empowered people, and advanced technologies, to
achieve cooperation and innovation in response to the need to supply our
customer with high quality customized products.
Seven Wastes Found in Manufacturing (Toyota) - ANSWER 1.Waste of
Waiting time
2.Transportation waste
3.Processing waste
4.Inventory waste
, 5.Waste of motion
6.Waste from overproduction
7.Waste from product defects
Nine Wastes Found in Manufacturing (Canon) - ANSWER 1.Waste Caused by
Work-in-Process
2. Waste Caused by Defects
3.Processing waste
4. Waste in Equipment
5.Waste in Expense
6.Waste in Planning
7.Waste in Human Resources
8.Waste in Operations
9.Waste in Startup
Basic Elements of Lean Manufacturing - ANSWER •Elimination of Waste
•Equipment Reliability
•Process Capability
•Continuous Flow
•Material flows one part at a time
•Less inventory
•Reduced defects
•Lead time reduction
•Error proofing
•Stop the line quality system
•Kanban system
•Standard Work
•Visual management
•In station process control
•Level production
•Takt time
•Quick changeover
Kaizen - ANSWER A culture of sustained continuous improvement focusing
on continuous improvement focusing on eliminating waste in all systems and
eliminating waste in all systems and processes of an organization.
Two Elements of Kaizen - ANSWER 1. Improvement/change for the better
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