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LEAN OPERATIONS - Coggle Diagram
LEAN OPERATIONS
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Process Design
Small Lot Sizes - moving through the system, in-process inventory is considerably less than it is with large lots.
Setup time reduction - Workers are often trained to do their own setups. Reduced setup time and cost are used to achieve the desired results, deliberate efforts are required, and workers are usually a valuable part of the process.
Manufacturing cells - machines and tools needed to process families of parts having similar processing requirements. important benefits of manufacturing cells are reduced changeover times, high utilization of equipment, and ease of cross-training operators.
Quality improvement - never-ending quest for quality improvement, focuses on finding and eliminating the causes of problems so they do not continually crop up.
Use Autonomation (Jidoka): Automatic detection of defects during production
Production flexibility - reduce downtime due to changeovers by reducing changeover time. Use preventive maintenance on key equipment to reduce breakdowns and downtime.
A balanced system - Line balancing of production lines helps to achieve a rapid flow of work through the system. The time needed for work assigned to each workstation must be less than or equal to the cycle time.
Little inventory storage - gradually in order to uncover the problems. Low inventories are the result of a process of successful problem solving.
Fail-Safe methods - building safeguards into a process to reduce or eliminate the potential for errors during a process (Poka-yoke).
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Just in Time (JIT)
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goods move through the system, and services are
performed
Supplies and components are "pulled" through system to arrive where they are needed when they are needed
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Product Design
Standard parts - workers have fewer parts to deal
with, and training times and costs are reduced
Modular design - parts treats as a single unit. This greatly reduces the number of parts to deal with, simplifying assembly, purchasing, handling, and training.
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Concurrent engineering - very disruptive to smooth operations. Concurrent engineering practices can substantially reduce these disruptions.
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Supporting Goals
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Make system flexible
robust enough to handle a mix of products, often on a daily basis, and to handle changes in the level of output while still maintaining balance and throughput speed.
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A flexible system of operation that uses considerably fewer resources than a traditional system. example: activities, people, inventory, and
floor space