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24 Cards in this Set
- Front
- Back
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Manufacturing engineers |
Find ways to meet customer’s expectations as lead time, mass customization, increase quality, increase warranty and environmental consideration |
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Manufacturing managers |
Have higher technical knowledge and spend more time behind a computer |
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Toyota production system TPS |
Japanese manufacturing sector developed by toyota. Organizes manufacturing and logistics for the automobile manufacturers. Including iteration with suppliers and customers. Must be used using minimum resources of manpower flow production and machinery |
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TPS wants to provide |
Best quality, lowest cost and short lead time through the elimination of waste. TPS maintain and improved though standardizes work and kaizen |
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JIT- just in time production |
Making what customer needs when it’s needed in the quantity needed |
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What does JIT do? |
Attacks waste Anything not adding value- from customers perspective Exposes problems and bottlenecks caused by variety Archives streamlines production- reducing inventory |
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Takt time |
Available time(includes all shifts) / product demand(exacly what you need) |
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Seven types of waste |
Over-production, wait time, transportation, processing, inventory, motion and defects |
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Mass production vs lean production |
Mass- batching and queuing Lean- continues flow |
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Pull vrs push JIT systems |
Pull- material is pulled to workstation just as its needed
Push- material is pushed into downstream workstations regardless whether resources are available |
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KANBAN |
Japanese word for card Autorizes production from downsteam operations through plants |
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Inventory |
Traditional- high inventory JIT- eliminates inventory JIT requires small lots, low ser up, and containers for fix number of parts |
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Heinjunka |
Leveling (smoothly) production schedule using mixed model sequencing Reduces ripple of smallvariations in schedukes. Production quantiries can be evenly distributed over time |
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Quick set up- quick changeover |
Reduce cost set up, reduce set up time SMED - single minute exchange of dies |
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Set up components |
Internal- must be performed while the machine is stopped External- can be carry out while the machine is still operating Aim convert as much of internal to external and improve set up |
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Jidoka |
Automation with a human touch Can result on a high performance and high speed production. But NOT toyota Toyota must have the ability to stop if something unusual happens. |
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Jidoka concept |
Doing it right at the first time, allow workers to stop production time, lights signal quality problems, under capacity scheduling, allows for planning, problem solving and maintenance, visual control makes problems viable. Poka yoke prevents defects |
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Jidoka technique- poka |
A form of device for building in quality May take many shapes and design Eg sensors, lights, alignment methods Goal- zero defects, find it before they occur Statistical quality control SQC - finding defects after they occur |
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Kaizen |
Breaking down the current situation, analyzing it and quickly putting it back together to make it better. “Change for better”- continuous improvement |
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Kaizen workshop |
5 days activity in which a team identifies and implements a significant improvement process |
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GEMBA |
Meaning real place where actions takes place Manufacturing have 3 main activities - developing, producing and selling products |
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Gemba 5 rules |
1- when a problem arises, go to GEMBA first 2- check gembustu (relevant objects) 3- take temporary counter-measures on the spot 4- find toot cause 5- standardize to prevent recurrence |
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5S |
Seiri (sort)- keep only what is absolutely necessary Seiton (organize/straighten) create a location for everything Seiso(cleanliness/sweep) clean everything and keep it clem Seiketsu (standardize) implement seiri, seiton and seiso plant wide Shitsuke (sustain) assure everyone floows 5s |
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Red flag attack |
A group of people that out red tags in everything not ised in the past 30 days, if the manager wants to keep it it need to justify it or they will be removed |
