Question

Lean Manufacturing:

1. Define and explain the following terms and concepts in association with lean manufacturing: Jidoka, kaizen, poke yoke, just-in-time, kanban and muda

2. In relation to inventory control, how pull system and push system are different from each other? Explain.

3. Identify one advantage and one limitation of flexible manufacturing system.

4. Make e a list of eight types of wastes with respect to lean manufacturing.

5. Describe major objective of lean manufacturing, and identify its limitation.

Answer 1

1.

Jidoka: Design equipment to partially automate the manufacturing process (partial automation is typically much less expensive than full automation) and to automatically stop when defects are detected. After Jidoka, workers can frequently monitor multiple stations (reducing labor costs) and many quality issues can be detected immediately (improving quality).

Kaizen:

A strategy where employees work together proactively to achieve regular, incremental improvements in the manufacturing process. It combines the collective talents of a company to create an engine for continually eliminating waste from manufacturing processes.

Poke yoke:

Design error detection and prevention into production processes with the goal of achieving zero defects. It is difficult (and expensive) to find all defects through inspection, and correcting defects typically gets significantly more expensive at each stage of production.

Just-in-time:

Pull parts through production based on customer demand instead of pushing parts through production based on projected demand. Relies on many lean tools, such as Continuous Flow, Heijunka, Kanban, Standardized Work and Takt Time. Highly effective in reducing inventory levels. Improves cash flow and reduces space requirements.

Kanban:

A method of regulating the flow of goods both within the factory and with outside suppliers and customers. Based on automatic replenishment through signal cards that indicate when more goods are needed. Which eliminates waste from inventory and overproduction. Can eliminate the need for physical inventories (instead relying on signal cards to indicate when more goods need to be ordered).

Muda:

Anything in the manufacturing process that does not add value from the customer’s perspective. It doesn’t. Muda means ‘waste’. The elimination of muda (waste) is the primary focus of lean manufacturing.

2.  

The Push System of Inventory Control

The push system of inventory control involves forecasting inventory needs to meet customer demand. Companies must predict which products customers will purchase along with determining what quantity of goods will be purchased. The company will in turn produce enough product to meet the forecast demand and sell, or push, the goods to the consumer.

Pull System of Inventory Control

The pull inventory control system begins with a customer's order. With this strategy, companies only make enough product to fulfill customer's orders. One advantage to the system is that there will be no excess of inventory that needs to be stored, thus reducing inventory levels and the cost of carrying and storing goods.

In general, we think push systems are better for large businesses that already have a healthy bottom line. It also helps to have a long history of sales data so you can accurately forecast customer demand. Meanwhile, pull systems tend to work better for smaller businesses that can’t afford to order and store their inventory in bulk.

3.

Advantage: Which reduce the costs of operation because their ability to adapt to changes helps to prevent defective products as well as wasted time and resources. On top of that, twhich require fewer workers to operate them compared to other manufacturing systems, so companies can save on labor costs.

Disadvantage: There are a few disadvantages of flexible manufacturing systems that many companies should consider. The most important is that implementing them in the production process can be complicated. It requires extensive planning, which can involve creating detailed designs and schedules.

4.  

• Defects: Defects impact time, money, resources and customer satisfaction.
• Excess Processing: Excess processing is a sign of a poorly designed process.
• Overproduction: When components are produced before they are required by the next downstream process, overproduction occurs.
• Waiting: Waiting can include people, material equipment (prior runs not finished) or idle equipment (mechanical downtime or excess changeover time).
• Inventory: Inventory is considered a form of waste because of the related holding costs.
• Transportation: Poor plant design can cause waste in transportation.
• Motion: Motion costs money. This not only includes raw materials but also people and equipment.
• Non-Utilized Talent: The eighth waste is the only lean manufacturing waste that is not manufacturing-process specific. This type of manufacturing waste occurs when management in a manufacturing environment fails to ensure that all their potential employee talent is being utilized.

5.

Objective: To recap, the goals of lean manufacturing are to improve the quality of products, eliminate unnecessary waste, reduce production times and reduce total costs.

Disadvantages of Lean Manufacturing

Equipment Failure - Lean has very little room for error. Equipment or labor failure can lead to major inconsistencies within lean and can make the entire operation fall behind. In other mass production facilities, employees could just move over to another machine if one went out