Lean Production Quiz

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Questions and Answers

What is the primary objective of the Toyota Production System?

To enhance marketing strategies

To increase production efficiency by eliminating waste (correct)

To promote employee independence

To maximize inventory turnover

Which of the following is NOT one of the Seven Deadly Wastes in lean production?

Employee Engagement (correct)

Defects

Transportation

Overprocessing

What does 'inventory' waste refer to in the context of lean production?

The cost of labor used in managing supplies

Costs involved in excessive production

Costs associated with loss, obsolescence, and damage to inventories (correct)

Costs associated with warehousing

Which of these actions would be categorized under 'motion' waste?

Walking between workstations without a purpose Signup and view all the answers

What is the implication of 'waiting time' as a type of waste?

It involves idle workers due to completion of tasks or machine issues Signup and view all the answers

What is the main benefit of reducing batch sizes in production?

Reduce lead times and improve workflow efficiency. Signup and view all the answers

Which production schedule would likely lead to better maintenance practices?

Continuous flow production with small lot sizes. Signup and view all the answers

What is a significant drawback of maintaining large batch production?

Higher levels of work-in-progress inventory. Signup and view all the answers

Given a monthly production requirement of 1,000 units each for Sedan and Coupe, what would be the most efficient scheduling method?

Produce Sedans and Coups in alternating daily batches. Signup and view all the answers

What is one of the poor outcomes associated with large lot size production?

Increased downtime for machine maintenance. Signup and view all the answers

How does lean operations management suggest handling variety within production?

By employing flexible scheduling techniques. Signup and view all the answers

Which method is favored in lean operations to minimize waste?

Cutting batch sizes to reduce waiting times. Signup and view all the answers

What challenge might arise from excessive focus on reducing batch sizes?

Higher costs of frequent equipment changeovers. Signup and view all the answers

Which of the following is NOT considered a form of waste in Operations Management?

Production scheduling Signup and view all the answers

What is the primary goal of the JIT (Just-In-Time) fundamental principles?

Eliminate waste Signup and view all the answers

Which of the following represents a secondary impact of defects found at the end of the line?

Loss of market share Signup and view all the answers

In the context of Kanban systems, what does ‘exposing hidden problems’ refer to?

Identifying inefficiencies in the workflow Signup and view all the answers

Which production schedule minimizes waste by balancing allocation over time?

Leveled Production Schedule Signup and view all the answers

What does the term 'Poka-Yoke' refer to in operations management?

A fool-proof design to prevent errors Signup and view all the answers

What is the primary focus of the pull production system?

To produce based on customer demand triggering execution Signup and view all the answers

Which of the following would NOT be a result of overproduction?

Increased customer satisfaction Signup and view all the answers

Which practice is suggested to enhance production efficiency and reduce waste?

Implementing a pull system Signup and view all the answers

What is a key characteristic of a Kanban system?

It uses cards to signal when to produce or withdraw items. Signup and view all the answers

What is a significant consequence of defects identified during the delivery phase?

Significant warranty costs for the company Signup and view all the answers

What tradeoff must be considered when implementing Heijunka?

Switchover costs vs. inventory costs Signup and view all the answers

Who is credited with developing the foundational ideas behind the pull system in production management?

Taiichi Ohno Signup and view all the answers

Which of these systems can be part of implementing a Kanban strategy?

Kanban squares Signup and view all the answers

In an unleveled production schedule, how are items produced?

Determined by forecasts of demand Signup and view all the answers

What is the primary difference in inventory management between traditional systems and JIT systems?

JIT systems operate with minimal necessary inventory. Signup and view all the answers

How do the lot sizes differ between traditional systems and JIT systems?

Traditional systems use large lot sizes. Signup and view all the answers

What is a characteristic of JIT system relationships with vendors?

Partnerships are emphasized. Signup and view all the answers

In what way does Noodles & Co. manage overprocessing?

By cooking each dish in separate pans. Signup and view all the answers

What approach does Noodles & Co. take to reduce waiting time for customers?

Ensuring customers don’t wait more than 5 minutes on average. Signup and view all the answers

How can TPS be applied to reduce waste in a hospital setting?

By reducing the number of unnecessary MRIs. Signup and view all the answers

What type of waste does placing supplies directly in patient rooms address?

Waiting time. Signup and view all the answers

What is a key characteristic of the delivery approach in JIT systems?

Deliveries are frequent and in small quantities. Signup and view all the answers

What is the primary goal of the production management system known as TPS?

To achieve the 'ideal' through continuous improvement Signup and view all the answers

Which of the following is NOT a pillar of TPS?

Cost cutting: Efficiency Signup and view all the answers

What technique is used in root cause analysis that involves repeatedly asking 'why'?

5 Whys Signup and view all the answers

What does kaizen primarily focus on in a production setting?

Continuous improvement of processes Signup and view all the answers

Which statement is true regarding the use of common handles on Box A and Box B?

It may increase costs due to higher handle prices for Box B. Signup and view all the answers

In the context of Jidoka, what does 'quality at source' refer to?

Ensuring quality issues are addressed during the production process Signup and view all the answers

What outcome does the self-learning process in continuous improvement aim to achieve?

To learn and improve upon the previous performance Signup and view all the answers

What issue was identified through the root cause analysis related to flat head screws?

They often break during the assembly process. Signup and view all the answers

Study Notes

Lean Operations

Lean operations is a system that aims to eliminate waste.
Toyota Production System (TPS) is the foundation of Lean operations.
Taiichi Ohno, the founder of TPS, stated that the most important objective is to increase production efficiency by consistently and thoroughly eliminating waste and respecting humanity.

Toyota Production System Philosophy

The core objective of TPS is to increase efficiency through consistently and thoroughly eliminating waste
Respect for humanity is an equally important concept
These concepts are the foundation of the Toyota Production System.

Toyota Production System Lean Production

Goal: highest quality, lowest cost, shortest lead time
Just-in-Time: continuous flow, takt time, pull system
Jidoka: stop and notify of abnormalities, separate human and machine work
Heijunka: standardized work, stability
Kaizen: continuous improvement

The Seven Deadly Wastes (TIMWOOD)

Transportation: moving materials between workstations without adding value.
Inventory: costs associated with loss, obsolescence, damage, and excess inventory.
Motion: movement unrelated to adding value to the product.
Waiting time: workers idle because they've completed their work or watch machines.
Overproduction: producing more than the market demands.
Over-processing: workers spend more on a flow unit than necessary
Defects: costs of scrap, rework, and defective output reaching the customer.

Forms of waste

Transportation
Inventory
Motion
Waiting time
Overproduction
Over-processing
Defects

Reducing waste: Increasing problem visibility

Lower inventory = Increased problem visibility
Lower the water to expose the rocks.

Reducing Waste: Cut Batch Sizes

Batch Shop (lot size=5)
Flow Shop (lot size=1)

How to run Lean Operations: Managing Variety

Monthly Production Requirement:
- Sedan: 1000
- Coupe: 1000

Reducing Waste: Heijunka

Level Production Schedule (AAAAABBBBB...) vs. Un-level Production Schedule (ΑΒΑΒΑΒ...)
Tradeoff? Switchover costs vs. Inventory costs

Implementation of Pull System: Kanban

Cards typically carried in transparent covers
Various systems using one or more Kanban cards (come in matching sets)
Move(Withdrawal) Kanban (card)
Production Kanban
- Example: Move Kanban: item no: P447, box capacity, preceding process, subsequent process. Production Kanban: item no.: P447, process: xxx, yyy

Kanban Card

Product Line 1
Material: PWH-MSTK
Material Description/Material Kurztext: Bosch Polkern 1 263 104 811
Size/Menge: 320'000
Shipping Unit/Transporteinheit: 1 x
Additional Kanban details

Video Kanban

Kanban system example
https://www.youtube.com/watch?v=5hoTWwtYEQo

Forms of Waste (repeated - emphasizing different order)

Transportation
Inventory
Motion
Waiting time
Overproduction
Over-processing
Defects

Motion

Waste of motion is any motion of man and/or equipment that does not add value.
Wasteful motion caused by:
- Poor workstation layout
- Excessive walking, bending
- Reaching
- Poor method design (transferring parts from one hand to another)
- Poor workspace organization
- Large batch sizes
- Reorientation of materials

Reducing Waste Pays Off: Quality at the Source

Defects found at each stage impacting the company in different ways
Showing financial impacts for different defects found.

Poka-Yoke (Fool-proof Design)

Diagram showcasing a foolproof design

Just-in-Time Fundamental Principals

1. Eliminate Waste
1.1. Overproduction
1.2. Excess Inventory
1.3. Products waiting in queues
1.4. Unnecessary moves (poor layout)
1.5. Large setup times
1.6. Waiting due to shortage, scheduling, and expediting
1. Reduce Inventory
2.1. Expose hidden problems
1. Meet Exact Needs at Exact Time
3.1. Small lot size
3.2. Pull system
3.2.1. High degree of planning
3.2.2. Flexibility
3.2.3. Level production
3.2.4. Minimum difference in products

Standardize

Using common handles in boxes improves savings; even though the cost of the handle may be higher on box B.

Jidoka (Automation)

Andon cord

Root Cause Analysis - 5 Whys

Examples given using 5 whys to find the root cause

Continuous Improvement (Kaizen)

Self-learning process:
Produce a part and learn how to produce better next time
Serve a client AND learn how to serve better next time
Teach a class and learn how to teach better next time

Summarize TPS

TPS is a production management system aiming for the "ideal" through continuous improvement (Kaizen)
Includes, but goes beyond JIT
Pillars: Synchronization (Heijunka), Quality at Source (Jidoka, Poka-Yoke), Continuous Improvement (Kaizen, Waste reduction)

Comparison of Systems (Traditional vs. JIT)

Tables comparing Traditional and JIT systems regarding Inventory, deliveries, lot sizes, Setup/Runs, Vendors. Workers, and Assets

Video: Noodles and Co.

Lean Production in a service company e.g, a restaurant
Video link

Noodles and Co. (Waste types)

Examples of how Noodles reduces each waste type (Transportation, Inventory, Motion, Waiting time, Overproduction, Over-processing, Defects)

TPS Applied to a Hospital

Reduce overproduction by reducing the number of MRIs done without extensive criteria.
Reduce waste in the form of motion.
Reduce waiting time, improve appointment system, elimination of waiting rooms.
Creating a flow manager in the hospital.

When does JIT not work?

Requires implementation throughout the supply chain
Workers need to accept responsibility for process changes, good management (cede control)
Kanbans for unique jobs, customizable processes.
JIT based on aggregate forecasts for planning purposes. Poorly handled unpredictable demand.

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Description

Test your knowledge on the principles of Lean Production and the Toyota Production System. This quiz covers topics such as the Seven Deadly Wastes, types of waste, and their implications in production efficiency. See how well you understand the concepts of waste reduction in a manufacturing context.