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?

<p>Walking between workstations without a purpose (C)</p> Signup and view all the answers

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

<p>It involves idle workers due to completion of tasks or machine issues (A)</p> Signup and view all the answers

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

<p>Reduce lead times and improve workflow efficiency. (C)</p> Signup and view all the answers

Which production schedule would likely lead to better maintenance practices?

<p>Continuous flow production with small lot sizes. (B)</p> Signup and view all the answers

What is a significant drawback of maintaining large batch production?

<p>Higher levels of work-in-progress inventory. (D)</p> 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?

<p>Produce Sedans and Coups in alternating daily batches. (C)</p> Signup and view all the answers

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

<p>Increased downtime for machine maintenance. (B)</p> Signup and view all the answers

How does lean operations management suggest handling variety within production?

<p>By employing flexible scheduling techniques. (D)</p> Signup and view all the answers

Which method is favored in lean operations to minimize waste?

<p>Cutting batch sizes to reduce waiting times. (B)</p> Signup and view all the answers

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

<p>Higher costs of frequent equipment changeovers. (D)</p> Signup and view all the answers

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

<p>Production scheduling (A)</p> Signup and view all the answers

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

<p>Eliminate waste (C)</p> Signup and view all the answers

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

<p>Loss of market share (D)</p> Signup and view all the answers

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

<p>Identifying inefficiencies in the workflow (C)</p> Signup and view all the answers

Which production schedule minimizes waste by balancing allocation over time?

<p>Leveled Production Schedule (A)</p> Signup and view all the answers

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

<p>A fool-proof design to prevent errors (C)</p> Signup and view all the answers

What is the primary focus of the pull production system?

<p>To produce based on customer demand triggering execution (A)</p> Signup and view all the answers

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

<p>Increased customer satisfaction (C)</p> Signup and view all the answers

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

<p>Implementing a pull system (B)</p> Signup and view all the answers

What is a key characteristic of a Kanban system?

<p>It uses cards to signal when to produce or withdraw items. (A)</p> Signup and view all the answers

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

<p>Significant warranty costs for the company (C)</p> Signup and view all the answers

What tradeoff must be considered when implementing Heijunka?

<p>Switchover costs vs. inventory costs (A)</p> Signup and view all the answers

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

<p>Taiichi Ohno (A)</p> Signup and view all the answers

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

<p>Kanban squares (B)</p> Signup and view all the answers

In an unleveled production schedule, how are items produced?

<p>Determined by forecasts of demand (A)</p> Signup and view all the answers

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

<p>JIT systems operate with minimal necessary inventory. (D)</p> Signup and view all the answers

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

<p>Traditional systems use large lot sizes. (D)</p> Signup and view all the answers

What is a characteristic of JIT system relationships with vendors?

<p>Partnerships are emphasized. (A)</p> Signup and view all the answers

In what way does Noodles & Co. manage overprocessing?

<p>By cooking each dish in separate pans. (A)</p> Signup and view all the answers

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

<p>Ensuring customers don’t wait more than 5 minutes on average. (A)</p> Signup and view all the answers

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

<p>By reducing the number of unnecessary MRIs. (B)</p> Signup and view all the answers

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

<p>Waiting time. (D)</p> Signup and view all the answers

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

<p>Deliveries are frequent and in small quantities. (D)</p> Signup and view all the answers

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

<p>To achieve the 'ideal' through continuous improvement (A)</p> Signup and view all the answers

Which of the following is NOT a pillar of TPS?

<p>Cost cutting: Efficiency (D)</p> Signup and view all the answers

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

<p>5 Whys (D)</p> Signup and view all the answers

What does kaizen primarily focus on in a production setting?

<p>Continuous improvement of processes (D)</p> Signup and view all the answers

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

<p>It may increase costs due to higher handle prices for Box B. (C)</p> Signup and view all the answers

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

<p>Ensuring quality issues are addressed during the production process (C)</p> Signup and view all the answers

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

<p>To learn and improve upon the previous performance (C)</p> Signup and view all the answers

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

<p>They often break during the assembly process. (D)</p> Signup and view all the answers

Flashcards

Toyota Production System (TPS)

A manufacturing system that emphasizes waste elimination and efficiency to maximize production value.

Lean Production

A production philosophy that focuses on minimizing waste and maximizing value in every process.

Seven Deadly Wastes (TIMWOOD)

A set of seven wasteful activities that should be eliminated in a lean production system.

Transportation Waste

Moving materials between workstations without adding value.

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Inventory Waste

Costs associated with excess inventory, loss, obsolescence, and damage.

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Batch Size

The number of units produced in a single production run. Smaller batch sizes allow for faster adjustments and reduced waste.

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Flow Shop

A production system where units flow through different processes in a sequential order, with a small batch size.

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Batch Shop

A production system where units are processed in large batches, often leading to longer waiting times and increased waste.

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Lead Time

The time it takes to complete a process, from start to finish.

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Waste

Any activity that does not add value to the customer.

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Lean Operations

A management philosophy focused on maximizing value for the customer while minimizing waste.

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Variety

The range of different products a company offers.

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Monthly Production Requirement

The target number of units to produce for each product type in a given month.

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Heijunka

A production leveling technique that aims to balance production volume and mix over time to minimize waste and improve efficiency.

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Leveled Production

A production system where the output rate of a process is balanced and consistent, avoiding peaks and valleys in production.

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Unleveled Production Schedule

A production schedule where output fluctuates significantly, leading to periods of high production and periods of low production.

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Tradeoff in Leveled Production

The balance between the costs of switching between production runs and the costs of holding inventory.

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Waste in Production

Any activity that consumes resources without creating value. Common types include transportation, inventory, motion, waiting time, overproduction, over-processing, and defects.

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Overproduction

Producing more than what is needed, leading to excess inventory and wasted resources.

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Push System

A production system where production is driven by the availability of inputs, regardless of demand.

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Pull System

A production system where production is triggered by actual customer demand, minimizing waste and maximizing efficiency.

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What is a Kanban card?

A visual representation of a task or work item in a Kanban system. It typically includes information like title, description, due date, and assignee.

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What is the purpose of the 'Forms of Waste' in Kanban?

Identifying and eliminating wasteful activities in a production process to improve efficiency and reduce costs.

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Motion Waste

Unnecessary movements of people or equipment, which can include inefficient layouts or unnecessary walking.

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Waiting Time Waste

When work items or resources are idle, waiting for the next step in the process, such as waiting for approval.

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Overproduction Waste

Producing more than what is needed or demanded by customers, leading to excess inventory and potential obsolescence.

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Over-processing Waste

Performing unnecessary work steps that don't add value to the product or service. It's like adding extra steps to a recipe that don't make the dish any better.

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JIT Inventory

A production strategy that aims to have only the minimum amount of inventory necessary to meet customer demand.

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JIT Deliveries

Frequent, small deliveries of materials, ensuring a continuous flow of production.

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JIT Lot Sizes

Smaller production runs, allowing for faster adjustments and reduced waste.

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JIT Setup and Runs

Reduced setup times and shorter production runs to improve efficiency.

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JIT Vendor Relationships

Long-term partnerships with suppliers, fostering collaboration and efficiency.

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Noodles & Co. Waste Reduction: Transportation

Minimizing unnecessary movement of food and supplies by having customers order and take their beverages before sitting down.

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Noodles & Co. Waste Reduction: Inventory

Reducing inventory waste by preparing food only after customers order, minimizing finished goods and work-in-progress.

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Noodles & Co. Waste Reduction: Motion

Optimizing kitchen layout like an assembly line, minimizing unnecessary movements for staff.

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Standardization in TPS

Using common components across different products to simplify production and reduce costs. For example, using the same handle for different boxes, even if the handle design is slightly more expensive for one box.

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Jidoka in TPS

Jidoka, or autonomation, empowers machines to detect and stop production in case of defects, preventing faulty products from being produced. An Andon cord is a visual signal used to alert operators of issues.

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Root Cause Analysis - 5 Whys

A problem-solving technique used to identify the root cause of an issue by asking 'why' five times in a row, drilling down to the fundamental problem. Like a detective, asking why can lead you to the original cause of the issue, not just a symptom.

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Continuous Improvement (Kaizen)

Kaizen is a philosophy of continuous improvement through small, incremental changes. It embraces a self-learning approach, where experience informs future actions. Kaizen is about making things better every single day.

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Synchronization in TPS

TPS emphasizes synchronization, or heijunka, to level production and smooth out demand peaks and troughs. This creates a more consistent production flow, avoiding overproduction.

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Quality at Source in TPS

TPS focuses on quality at the source, ensuring that each process is producing quality outputs. This involves techniques like Jidoka and Poka-Yoke, where defects are detected and prevented early on.

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What is the essence of TPS?

TPS is a comprehensive production system that goes beyond just-in-time (JIT) to achieve a continuous improvement (Kaizen) cycle, aiming for the ideal production flow. It emphasizes waste reduction and quality at the source.

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Why is TPS important?

TPS is important because it helps companies to produce better quality products at a lower cost. It's a powerful toolkit for optimizing operations.

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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.

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