Starter: Production Key Terms Look at the key terms below and then define them. Key Term Defined Job Production Flow Production Batch Production Cell Production

Starter: Production Key Terms Look at the key terms below and then define them. Key Term Defined Job Production Flow Production Batch Production Cell Production This is production that involves an item being manufactured entirely by one worker or by a group of workers. These items are often made to customer requirements, rather than being mass produced. They are a one off This is production that involves continuous production for each unit, often with the use of a moving conveyor belt (e.g. a car assembly line). This is production that has items being divided into a number of small tasks. A collection (or ‘batch’) of items each have one of these tasks completed, and then the batch moves onto the next manufacturing task. This is production that is organised workers into ‘cells’ within the factory, with each cell comprising several workers who each possess different skills these works then work together to produce one item.

Monday, 02 July 2018 Today you will know what lean production is. You will understand how businesses achieve lean production. You will be able to apply the concept to CLN.

What is Lean Production? Lean production is a collection of methods that attempt to reduce waste in the production process. It is inspired by Japanese manufacturing companies. Lean production includes: Cell production Just in time Time-based management Continuous improvement (kaizen)

What is the purpose of Cell Production? Splitting a continuous flow production line into self-contained units. Each unit produces a finished article. What is the purpose of Cell Production? Improve motivation through job rotation and enrichment and reducing boredom Gives satisfaction to workers To reduce absenteeism, turnover and trade union action Improve the quality of the product

Cell Production: The Benefits… Cell Production: Business Requirements Improved commitment and motivation Multi-skilled workers Flexibility of workers Product quality through ‘ownership’ Cell Production: Business Requirements Change layout and design of production line Empowerment of workers who set own targets which must be in line with corporate aims Change materials handling systems Self checking by employees

Just In Time Production… JIT Production… Stock arrives exactly when needed in production What is the purpose of JIT Production? Eliminates the need for stock Reduces waste, theft, perishing Reduce costs (warehousing, staff etc)

Just In Time Production… JIT Production: The Benefits… Time saving May not suffer from unsold stock as are able to respond to consumer change Responsive to customers changing tastes (product is pulled through production process by customer demand, rather than pulled traditionally) JIT Production: Business Requirements Excellent communication Skilled and flexible staff Good relations with suppliers

Time-Based Management Time based management is an approach that recognises the importance of time and seeks to reduce unproductive time What is the purpose of Time-Based Management? Produce shorter product development times Quicker response times Greater efficiency

Time-Based Management Time-Based Management: The Benefits… Time may be used as a USP e.g. AA Improved customer loyalty Gain early mover advantage in a market Time-Based Management: Business Requirements Simultaneous engineering Planning all tasks in a project at the same time using a teamwork approach involving product teams and suppliers

Kaizen: Continuous Improvement Kaizen – small incremental changes rather than large rethinks. What is the purpose of Kaizen: Continuous Improvement The purpose is to achieve better quality and greater efficiency Kaizen: Continuous Improvement: The Benefits Many small changes rather than few large ones which may seriously effect production levels and staff e.g. culture, uncertainty Kaizen: Continuous Improvement: Business Requirements Skilled staff who are able to make valid suggestions Encouragement by management to employees to make suggestions Democratic management

Lean Production Questions… Based on your knowledge of Lean Production complete the questions below: What is meant by the term lean production? (2 marks) Explain 3 benefits of lean production (6 marks) Evaluate the advantages of CLN developing a time-based management system. (10 marks) Evaluate how CLN might make use of Kaizen (Continuous Improvement) (10 marks)