Details Title: Lean Management 1st Test Description: for 1st test from book Total Flash Cards: 33 Created: 02/17/2009 12:20:51		New Users: To study from this flashcard set, or to create your own your own study flash cards, REGISTER HERE. Existing Users: CLICK HERE. Additional Management Flashcards
Cards in this set: Term Key One Level 1 Definition Cigarette butts, scrap paper, and tools and parts are left scattered Term Key One Level 2 Definition a. dispose of unneeded items i. Keep the floors clean ii. Get rid of things that will not be used soon Term Key 1 Level 2 Problems Definition i. Look at how things are placed ii. No pathways and some dirt and things in the corners Term Key One Level 3 Definition i. Clean up the equipment ii. Mark pathways and clear out the corners iii. Have regular “check-ups” with friendly competition Term Key One Level 3 Problems Definition i. Cabinets and desks are still cluttered with tools and other things Term Key One Level 4 Definition i. Clearly organize and mark all sections using right angles and parallel lines ii. Organize storage areas for tools and parts for each workstation iii. Use a labeling, numbering, or color-code system for shelf storage Term Key One Level 4 Problems Definition making sure things stay organized on days that aren’t inspection day Term Key One Level 5 Definition i. Earn a perfect score even during surprise inspections ii. Mark stock levels and quantities clearly iii. Devise ways to automatically dispose of wood chips, worn tools, etc. iv. Eliminate causes of dirt and disorder Term Key Two Level 1 Definition i. No clear management system ii. Each set of instructions begins with a superior iii. Workers avoid challenges iv. Frontline managers and workers have little idea of overall company scheme, and therefore work is duplicated Term Key Two Level 2 Definition i. Make an organization chart and specify details ii. Revise the chart to eliminate duplication of responsibilities and to fill gaps iii. Each person’s range and individual responsibilities are clearly defined Term Key Two Level 2 Problems Definition i. Top managers goals are clearly defined, but middle and lower managers don’t know what they mean Term Key Two Level 3 Definition "clockwork style" i. Instructions from top management are broken down into more detail at each level ii. Like the way gears on a clock work together, and graphs created to show inter-workings (monitor graphed progress Term Key Two Level 3 Problems Definition i. Goals are set but not well coordinated and employee cooperation is lacking Term Key Two Level 4 Definition i. Management levels work cooperatively in setting objectives and coordinating goals to achieve common goals ii. Each factory and section conducts a 20 Key evaluation iii. All managers understand the interrelations of the 20 Keys iv. Company strives toward 80% goals accomplished by mid-term at multilevel meetings, and must achieve 80% by annual multi-level meetings Term Key Two Level 4 Problems Definition i. Watch for groups that are having trouble accomplishing goals ii. Changes such as market conditions might change some vectors goals Term Key Two Level 5 Definition i. Be prepared to deal with changing conditions in the pursuit of goals ii. Work to create common goals, improve individual skills, and boost teamwork toward company goals iii. All groups (suppliers, manufacturing, R&D, and Sales) understand long-term 20 Keys and the goals iv. 80% of goals achieved by midterm multilevel meeting and 100% at the end of the year Term Key Three Level 1 Definition i. Employees have no desire to get involved in team activities ii. Look for the “easy way” instead of the “efficient way” Term Key Three Level 2 Definition i. Employee suggestion system is established ii. Company gets involved in starting team activities iii. Improvement suggestions climb to at least six per employee per year iv. Make suggestions performance AND people oriented Term Key Three Level 2 Problems Definition i. Employees lack enthusiasm for personal and independent growth Term Key Three Level 3 Definition i. Team activities are based on autonomous improvements ii. Groups complete at least two improvement projects each year iii. Each member submits at least one improvement per month iv. Hold frequent, stand up meetings during work hours to ensure they’re brief v. Teams are 3 to 7 people Term Key Three Level 3 Problems Definition i. Teams start off full of autonomous enthusiasm, but often lose the vigor ii. Dedicated support from managers is a must Term Key Three Level 4 Definition i. Improvement topics combine employee goals with company goals including “vector alignment” to bring all teams together ii. Improvement teams complete at least 4 improvement themes per year iii. Team members submit at least two suggestions per month Term Key Three Level 4 Problems Definition i. There are still 17 keys left to be implemented ii. When tough problems come up, managerial and technical assistance must be needed to discourage dampening enthusiasm Term Key Three Level 5 Definition i. After work activities where people can relax and enjoy themselves to promote mutual understanding and help align team goals w/ company goals ii. Morale is continually boosted through after-work activities to enable employee relations and boosted morale iii. Teams average six completed themes per year iv. Team members average five suggestions per month Term Key Four Level 1 Definition i. Work-in-process (WIP) is considered a “necessary evil” ii. When deliveries fall behind, they’re fixed by feeding in more materials Term Key Four Level 2 Action Definition i. Everyone must understand reducing WIP makes work easier ii. Waste is any activity w/out value iii. Reducing overproduction waste (WIP) makes all other waste easier to identify Term Key Four Level 2 Definition i. Inventory reduction campaigns are launched in pilot, small, areas ii. Inventory reduced in one part of the factory iii. The fewer the trays, the better the flow of paperwork Term Key Four Level 3 Action Definition i. Create a plant-wide program w/ guidelines for reducing inventory Term Key Four Level 3 Definition i. Start a handbook based plant-wide inventory reduction program ii. Also, sorting trays will reduce unnecessary paperwork inventory Term Key Four Level 4 Action Definition i. Reduce WIP by shortening the production line (reduce # of processes) ii. Implement small-lot production iii. Reduce WIP within and between processes Term Key Four Level 4 Definition i. Systemize both equipment and methodology ii. Reduce inventory by 75 % iii. Conversion to “pull production” which draws goods from the process upstream iv. Company has reached level 3 or higher in all 19 other keys Term Key Four Level 5 Action Definition i. Unite manufacturing, R&D, and sales in goal of satisfying customer needs ii. All parts, even suppliers, must be able to quickly and accurately respond to customer needs iii. Create a manufacturing system of only what’s needed only when needed Term Key Four Level 5 Definition i. Change adaptive manufacturing quality has been established ii. Company is more equipped to ensure customer satisfaction and value iii. Level 4 or better in all other 19 Keys iv. Inventory (including material and information) is reduced by 80%