Exam (elaborations)
10.2 LEAN MANUFACTURING TEST QUESTIONS AND ANSWERS
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10.2 LEAN MANUFACTURING TEST QUESTIONS AND ANSWERS,...
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Characteristics of lean production - ANSWER Include extremely limitedinventories, highly skilled workers, constant improvement in pursuit of
perfection including no tolerance for defects, high levels of product diversity
and customisation in an environment seeking cost reductions
Principles of lean production - ANSWER Are applied to the entire production
process, that is, from supply chains through to manufacturing. It is achieved
through well-designed quality control systems, with production volume and
customisation based directly on market demand.
Lean Production cost - ANSWER Cost reduction is achieved through the
elimination of wage and costly errors. Strong links with suppliers guarantee the
integrity of supply and maintain confidence to keep inventories as close to zero
as possible. The workforce is empowered to associate with the company's
quality goals and foster an environment of striving for constant improvement.
Lean production may be summarised by the application of the following
principles - ANSWER Flexibility
Visual control aids
Market pull processing
Managing production flow
Waste reduction or minimisation
Constantly seeking improvement
Strong long term relationships with suppliers
Error minimisation and perfect first time quality
Value stream mapping - ANSWER Is also known as end to end system
mapping. It is a simple but powerful tool that provides a visual aid to map the
relationships between materials, processes, information and time.
- ANSWER Initially a paper and pen exercise, v.aue stream mapping
documents the information associated with prodution from the reception of raw
materials through to product distribution. Today these maps are computer
generated and incorporate real time production data. The supporting data
accompanying production allows for detailed analysis which can be particularly
, useful when trying to reduce product cycle times. It is this insight into the chain
of decision making/cause and effect that can prove most useful
Purpose of value stream mapping - ANSWER Is to identify processes that do
not provide value. Processes that do not provide value are designated as waste.
Value stream maps may be used to optimise individual processes, whole of
factory production or even a age supply chains between multiple organisations.
What if scenarios may be simulated to model future production alternatives.
In the end, value stream mapping is used to identify areas of production that
may be able to be streamlined or improved. This proc so is an integral part of
lean manufacturing's philopshy of continuous improvement
Workflow analysis - ANSWER Supports value steaming and classifies all take
in a process. Tasks are categorised as value adding, value assisting or mom
value adding
Value adding activity or operation - ANSWER Transforms a component and is
an indispensable part of the overall process. These operations are the processes
for which a customer is willing to pay. Operations that are not categorised as
value adding should be simplified, streamlined, Reduced, integrated into other
activities or removed
Value assisting activity or operation - ANSWER Does not not add value to the
component, however, these operations are integral to the manufacturing process
and cannot be omitted. Preventive maintanance, inspection, statistical process
control etc. And so on are value assisting operations
Non value adding operations - ANSWER Are those activities that will not be
missed if they are removed from the process. These activities are often
categorised as waste. Delays, superfluous material movement, holding
inventory or storage are all seen as non value adding operations
Product family - ANSWER Is a grouping of products and their variants that all
pass through similar processing steps and common equipment just prior to
shipment to the customer. This part of the production is known as the
downstream end. Product families often used as the unit for analysis through
value stream maps
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