1. Starter: Lean Production Key Terms Look at the key terms below and then define them. Key TermDefined Just In Time (JIT) Kaizen (Continuous Improvement) Time Base Management Cell Production

2. Starter: Lean Production Key Terms Look at the key terms below and then define them. Key TermDefined Just In Time (JIT) Kaizen (Continuous Improvement) Time Base Management Cell Production Stock arrives exactly when needed in production. Eliminates the need for stock, reduces waste, theft, and perishing stock and therefore reduce costs (warehousing, staff etc) Kaizen – small incremental changes rather than large rethinks. The purpose is to achieve better quality and greater efficiency. It focuses on many small changes rather than few large ones which may seriously effect production levels and staff e.g. culture, uncertainty Time based management is an approach that recognises the importance of time and seeks to reduce unproductive time with shorter product development times, quicker response times and greater efficiency 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.

3. Read the case Study and then complete the following Questions: 1. Calculate the output per worker in 1988 and in 1989. (6 marks) 2. Ian Smith the Production Manager at the Cumbernauld factory tries hard to encourage a lean Production approach. What does this mean and what examples of this are evident in the case? (10 marks) 3. The implementation of a Total Quality Management Culture ensured the success of OKI (UK) Ltd. To what extent do you agree with this statement? (12 marks) OKI Printing Solution (UK) Ltd

4. 1. Calculate the output per worker in 1988 and in 1989. (6 marks) OKI Printing Solution (UK) Ltd Labour Productivity = Output of units (per annum) Number of employees 1988 Output:2,400 No of Workers: 300 1988 2,400= 8 printers per worker 300

5. 1. Calculate the output per worker in 1988 and in 1989. (6 marks) OKI Printing Solution (UK) Ltd Labour Productivity = Output of units (per annum) Number of employees 1989 Output:6,000 No of Workers: 600 1989 6,000= 10 printers per worker 600

6. 2. Ian Smith the Production Manager at the Cumbernauld factory tries hard to encourage a lean Production approach. What does this mean and what examples of this are evident in the case? (10 marks) OKI Printing Solution (UK) Ltd Start with a definition of Lean Production (AO1) Then explain what elements lean production are evident in the case study and explain the ‘Knock on Effect’ of these elements (their benefits and drawbacks on OKI) (AO2 & AO3) Consider: Cell production, Just in time, time-based management and continuous improvement (kaizen)

7. 3. The implementation of a Total Quality Management Culture ensured the success of OKI (UK) Ltd. To what extent do you agree with this statement? (12 marks) OKI Printing Solution (UK) Ltd Start with a definition of TQM (AO1) Then explain TQM involves and explain where / how they are evident in the case study and explain the ‘Knock on Effect’ of these elements (their benefits and drawbacks on OKI) (AO2 & AO3) Consider: Staff involvement (Quality Assurance), quality circles, quality culture and the impct on Motivation and quality of products at all stage of production. Then show judgement. Do you agree with the statement. YES /NO? Give detailed reasons and supportive evidence for your decision. (AO4)