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14 Cards in this Set
- Front
- Back
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What are the 3 things that a Lean Organization is about? |
-Continuous Imoprovement -The relentless pursuit of the elimination of waste. -Making processes that are Predictable
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What are 3 of the 6 Lean Principles? |
1. Specify value from the standpoint of the end customer 2. Identify all the steps in the value stream for each product family, – Eliminate whenever possible those steps that do not create value 3. Make the value-creating steps occur in tight sequence – Make the product flow smoothly toward the customer 4. As flow is introduced, let customers pull value from the next upstream activity 5. Seek Perfection by: – Identifying the value stream – Removing Wasted steps – Continuously Flowing and Pulling Product in each area 6. Continue the process until a state of perfection is reached – That is continue until perfect value is created with no waste |
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What are the 3 things that are the foundations of Lean? |
1. Standard Work 2. Kaizen 3. 5S |
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What are the 7 Wastes (Muda) |
1. Defects. 2. Over Processing 3. Over Production 4. Motion 5. Waiting 6. Inventory 7. Transportation |
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What are the 5Ss? |
1. Sort 2. Straighten 3. Shine 4. Standardize 5. Sustain
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What do you get when you accept? |
1. You get what you deserve |
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Never accept what? |
1. Lack of adherence |
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What are the 7 keys to Success? |
1. Training of the Workforce 2. Management / Leadership commitment and consistency to applying the 5S Standards 3. Never accept lack of adherence 4. Perform monthly random 5S Audits by Management 5. Accentuate the positive 6. Institute a Rewards and Recognition Program 7. When necessary immediately correct lack of adherence |
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What are the 7 steps to create a 5S Program? |
1. Ensure Executive Management Buy-In 2. Provide Time and Resources 3. Train 4. Implement the 5S Elements and their Tools 5. Assign a 5S Leader 6. Conduct 5S Audits 7. Institute Rewards and Recognition |
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What is Lean all about? |
1. Ensure the highest Quality Levels 2. Ensure On-Time Delivery 3. Obtain the Lowest Operational Costs |
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What are the 5S Elements about? |
1. Sort: The first step in making things cleaned and organized 2. Straighten: Organize, identify and arrange everything in a work area 3. Shine: Regular cleaning and maintenance 4. Standardize: Make it easy to maintain 5. Sustain: Maintain what has been accomplished, measure and correct immediately |
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Name 4 of the 9 tools used in 5S |
1. Process Flow Charts 2. Process White Boards 3. Shadow Boards 4. Kanbans 5. Standard Operating Procedures (SOP) by Discipline 6. Preventive Maintenance List 7. Cleaning Schedule 8. 5S Audits 9. 5S Metrics |
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Name 4 of the 14 reasons Why 5S programs fail |
1. Senior Management would not participate in GEMBA Walks 2. They would not enforce adherence to 5S Standards 3. They did not take immediate corrective action 4. There was not a 5S Audit Team 5. There was not a 5S Leader 6. Management failed to fully support by providing time and resources 7. Lack of discipline (some employees avoid cleaning and straightening at all costs) 8. The checklists were not followed or were not clear and to the point 9. The audit was not done consistently and properly 10.The results of the audit were not communicated and nobody was assigned to fix the problem, with a deadline 11.The employees were not trained properly in 5S 12.The employees were not made responsible for 5S 13.Everyone was not made to feel that they are “owners” of the operation 14.Recognition and rewards were not in place |
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What are the 4 Things a Lean Leader must do? |
- Train - Lead by Example - Mentor - Discipline, when necessary |
