DM307: Continuous Improvement

What are the 5 Principles of Lean

Identify Value
Map the Value Stream
Create Flow
Establish Pull
Pursue Perfection

What are the 4 Goals of Lean

Improve Quality
Eliminate Waste
Reduce Lead Time
Reduce Cost

What are the 8 Wates of Lean

Defects
Overproduction
Waiting
Non-utilized Talent
Transportation
Inventory
Motion
Extra Processing

What is the definition of Kaizen

Kaizen means "continuous improvement.” It focuses on small, incremental changes in processes, products, or systems to improve efficiency, quality, and performance. It involves everyone—from top management to shop floor workers. Signup and view all the answers

What is the Kaizen Cycle (PDCA Cycle)

P – Plan Identify a problem or area for improvement. Analyze the situation and develop a plan for change. D – Do Implement the change on a small scale to test its effect. C – Check Monitor and evaluate the results. Compare actual results to the expected outcomes. A – Act If successful, standardize the change and implement it on a larger scale. If not, revise the plan and repeat the cycle. Signup and view all the answers

What are the 5 Gs

Actual place: Go to the actual place where work happens to understand the situation first hand. Actual thing: Look at the actual object or item involved in the issue. Actual facts/data: Rely on data and facts—not assumptions. Principle: Understand the fundamental theories behind what's happening. Standard: Follow standard procedures and rules. Signup and view all the answers

What are the 3M's (The Targets for Elimination)

Waste: Any activity that doesn’t add value (e.g., overproduction, waiting time, excess inventory). Inconsistency: Unevenness or irregularity in operations or demand (e.g., workflow imbalance). Overburden: Pushing people or machines beyond their limits, leading to breakdowns and errors Signup and view all the answers

What are the 3 Principles of Poke Yoke?

Errors are predictable – They tend to occur in patterns and can be anticipated through analysis. Errors are preventable – With proper systems and design, the likelihood of human error can be significantly reduced. Systems influence behaviour – Poorly designed systems or environments often contribute to errors, rather than individual incompetence. Signup and view all the answers

For Poke Yoke what are the types of Human Errors

Slips – Unintended actions due to attention failure (e.g., pressing the wrong button). Lapses – Memory failures, such as forgetting to perform a step. Mistakes – Errors in planning or decision-making due to lack of knowledge or incorrect judgment. Violations – Deliberate deviations from procedures or rules. Signup and view all the answers

For Poke Yoke what are the causes of human error?

Fatigue or stress Poor communication Inadequate training Complex or confusing instructions Poor user interface or system design Environmental factors (e.g., noise, lighting) Signup and view all the answers

What are the types of Poke Yoke?

Control Poka-Yoke – Prevents the error from occurring by stopping the process or restricting movement (e.g., jigs, limit switches). Warning Poka-Yoke – Alerts the user that an error may occur (e.g., buzzers, lights, alarms). Signup and view all the answers

What are the mechanisms of Poke Yoke devices

Contact Method – Detects physical characteristics like shape, size, or color. Fixed-value Method – Ensures a specific number of movements or parts are present. Motion-step Method – Verifies that all required steps have been completed in the correct sequence. Signup and view all the answers

What is the Theory of Constraints (TOC)

The Theory of Constraints (TOC) is a management philosophy developed by Eliyahu M. Goldratt, which focuses on identifying the most critical limiting factor (i.e., the constraint) that hinders a system's ability to achieve its goals, and then systematically improving it until it is no longer the limiting factor. The main idea: “A chain is only as strong as its weakest link.” Signup and view all the answers

What are the The Five Focusing Steps of TOC?

Identify the Constraint: Find the part of the system (process, resource, policy, etc.) that limits overall performance or output. Exploit the Constraint: Maximize the use of the constraint without major investment. Make sure it's always working on value-added tasks. Subordinate Everything Else: Align all other processes to support the maximum efficiency of the constraint. Elevate the Constraint: If the constraint still exists, take further actions (invest in upgrades, hire more people, etc.) to eliminate or expand it. Repeat the Process (Go Back to Step 1): Once one constraint is resolved, another will surface. Continuously improve by repeating the steps. Signup and view all the answers

What are the types of constraints in TOC?

Physical Constraints: Limitations of physical resources (e.g., machines, people, materials). Policy Constraints: Rules or procedures that limit performance (e.g., outdated rules, inefficient workflows). Market Constraints: Limitations in demand or market size – the system can't sell more than the market wants. Logistical Constraints: Issues related to coordination, lead times, or scheduling. Behavioral Constraints: Human-related issues such as resistance to change or poor communication. Signup and view all the answers

What is Drum Buffer Rope (DBR) strategy in TOC?

Drum-Buffer-Rope (DBR) is a TOC-based production scheduling method designed to protect the constraint and maintain throughput. Drum: The constraint (bottleneck) sets the pace for the entire system – it’s the "drumbeat" everyone follows. Buffer: A time buffer placed before the constraint to ensure it never runs out of work, absorbing variability and delays. Rope: A communication mechanism that ensures upstream activities release materials at the right time to avoid overproduction and WIP (work in progress) buildup. In simple terms: Drum = what to produce Buffer = how much to protect the drum Rope = when to release work to match the drum Signup and view all the answers

DM307: Continuous Improvement - Summary

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