Operations managementLesson 4 of 4 in the course Supply chain management

Lean Manufacturing: Origins, Principles, and Implementation Risks

5 flashcards · 5 quiz questions · 5 match pairs · 4 fill-in sentences · English

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Summary

Lean manufacturing developed over many decades, drawing on scientific management, statistical methods, and the practical challenges faced by post-war Japanese industry. This lesson traces how these ideas grew into the Toyota Production System and spread to companies in the West.

In the early twentieth century, Frederick Winslow Taylor documented methods for improving manufacturing efficiency in Principles of Scientific Management (1911). Henry Ford applied some of these ideas in manufacturing. These approaches focused primarily on how physical work was organized; they did not yet provide a complete management system or address workplace culture in the way later Lean practices would.

All flashcards

How is Lean broader than just-in-time (JIT)?
JIT focuses on receiving goods when needed; Lean also improves the wider system and its processes.
What are the seven classic categories of waste in Lean?
Inventory, overproduction, over-processing, transportation, excess motion, waiting, and defects.
What role do workers play in continuous Lean improvement?
Workers identify abnormalities, help solve problems, and improve standard work.
What is value stream costing?
A Lean accounting method that collects actual costs against each value stream.
How can organizations reduce supply-chain risks while using low inventory?
They can keep strategic stockpiles of critical goods and diversify suppliers.

Quiz questions

  1. In Lean, what makes an activity valuable from the customer's perspective?Answer: It contributes to something the customer wants and is willing to pay for.
  2. Which Lean waste describes making more than is currently needed or making it too soon?Answer: Overproduction
  3. After identifying the value stream and challenging non-value-adding steps, which Lean principle arranges remaining steps to move smoothly?Answer: Flow
  4. When continuous flow is not feasible, what does the Lean principle of pull coordinate?Answer: An upstream step responding to a downstream need.
  5. Which approach can help protect a low-inventory supply chain from disruptions?Answer: Keep strategic stockpiles of critical goods and diversify suppliers.

Based on the Wikipedia article Lean manufacturing, licensed CC BY-SA 4.0. Adapted into a summary, flashcards and quizzes.

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