Aircraft systems

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Lean systems are Operations systems that maximize the value added by each of a company’s Activities by removing waste and delays from them.

Toyota Production System (TPS)

Just-in-time (JIT) system

JIT philosophy – Eliminate waste or muda by cutting unnecessary capacity or inventory and Removing non-value-added activities

The goal is to Eliminate the eight types of waste, produce services and products only as Needed, and to continuously improve the value-added benefits of operations.

Close supplier ties

Look for ways to improve efficiency and reduce inventories Throughout the supply chain

JIT II: In-plant Representative

Supply Chain Considerations in Lean Systems

Small lot sizes: Reduce The average level of inventory. Pass Through system faster. Achieve uniform workload and prevent overproduction. Increase setup frequency

Process Considerations in Lean Systems

Pull method of work flow

Pull method vs. Push method

Quality at the source

Jidoka

Poka-yoke -- mistake proofing

Andon

Uniform workstation loads

Process Considerations In Lean Systems

Standardized components and work methods

Flexible workforce

Automation

Total Preventive Maintenance (TPM)

Five S (5S) practices

Designing Lean System Layouts

line flows

One worker, multiple machines (OWMM)

Group technology

Group parts or products with similar characteristics into Families

Eight types of waste Or muda

1 Overproduction: manufacturing an item before it is needed

2 Inappropriate processing: using expensive high precision Equipment when simpler machines would suffice

3 Waiting: wasteful time incurred when product is not being Moved or processed

4 Transportation: excessive movement and material handling Of product between processes

5 Motion: unnecessary effort related to the ergonomics of Bending, stretching, reaching, lifting and walking

6 Inventory excess inventory hides problems on the shop Floor, consumes space

7 Defects: quality defects result in rework and scrap, and Add wasteful costs to the system in the form of lost capacity, rescheduling Effort, increased inspection and loss of customer good will

8 underutilization of employees: failure of the firm to Learn from and capitalize on its employees knowledge and creativity impedes Long term efforts to eliminate waste

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