9609 · 9.3.4
Lean production flashcards
Revision flashcards for Cambridge 9609 Lean production (syllabus 9.3.4). Flip, recall, then mark a real past-paper question.
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Lean goal?
Maximise value, minimise waste (muda).
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Seven wastes (examples)?
Overproduction, waiting, transport, inventory, motion, over-processing, defects.
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Pull vs push?
Pull = produce to order; push = produce to forecast/stock.
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Kaizen?
Continuous improvement — all staff suggest changes.
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5S?
Sort, set, shine, standardise, sustain — workplace organisation.
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Toyota Production System?
Reference model for lean + JIT + respect for people.
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Lean requirement?
Reliable suppliers, quality at source, flexible workforce.
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vs mass production?
Mass = high stock, economies of scale; lean = low waste, responsiveness.
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What is 'muda' in the context of lean production?
Muda is the Japanese term for waste. It refers to any activity that consumes resources but adds no value for the customer. The seven wastes are: Transport, Inventory, Motion, Waiting, Overproduction, Over-processing, and Defects.
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What is a 'pull system' of production?
A system where production is triggered by actual customer demand. An order from a customer 'pulls' the product through the manufacturing process. This is a core component of JIT and contrasts with a 'push system' based on forecasts.
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What is the core principle of Kaizen?
The core principle of Kaizen is continuous, incremental improvement involving all employees in an organisation, from senior management to the shop floor, to collectively identify and eliminate waste.
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What is the primary purpose of the 5S framework?
To create and maintain a clean, organised, safe, and efficient workplace. It is a foundational lean tool that makes waste and process abnormalities more visible and easier to address.
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What is the main disadvantage or risk of implementing a Just-in-Time (JIT) system?
The main risk is the lack of buffer stock, which makes the production process highly vulnerable to disruptions in the supply chain. Any delay or quality issue from a supplier can halt the entire production line.