1. Open the Worksheet: CRL/Year 11/Technology/Engineering/Unit 1/ Lean Manufacturing worksheet WLT Think about what you already know about lean manaufacturing and the 3 lean manufacturing techniques: Just- In- Time manufacturing Kaizen Poka- Yoke

2. Is the never ending effort to eliminate or reduce waste or any activity that consumes resources in design, manufacturing, and product distribution. http://www.youtube.com/watch?v=zUUVy59J_54 Three main areas of lean manufacturing are: Just- In- Time manufacturing Kaizen Poka- Yoke

3. This involves a strategic approach to the development and operation of a manufacturing system. This means that the production process is organised in a way that ensures parts are available when they are needed. Advantages: As products are made to customer orders, there is no overproduction, reducing the build up of stock or inventory such as raw materials and finished goods. A reduction in stock or inventory also reduces costs as there is less space required for storage of materials or finished goods. It reduces production cycle times quite drastically through automation and the use of minimal man power, further reducing costs. It recognises waste in the movement of materials within an organisation and changes the layout of the manufacturing line to improve efficiency. Involves the workers

4. Also known as continuous improvement, this is a policy of constantly introducing small changes to improve quality and efficiency. This technique puts the workers at the heart of the decision- making as they are the best people to suggest improvements. Advantages Improvements are based on small changes rather than large changes as a result of research and development. As the ideas come from the workers they are less likely to be much different than existing processes and are therefore easier to implement. Small changes generally do not cost a great deal of money when compared with any major process/ production changes. It encourages workers to take ownership of their work and reinforces team- working, leading to improved worker motivation. Involves workers and managers. http://www.youtube.com/watch?v=F_NCMHXSolE

6. This is a technique for the removal of simplistic human error in the workplace also known as mistake proofing and fail safe work methods. The idea is to take over all the repetitive process/ tasks performed by humans that rely on memory or vigilance and replace them with a simple system to improve productivity and quality. Advantages Eliminating set up errors, therefore improving quality Decreasing set up time and improving production output Increased safety as workers do not get injured through lack of concentration Reduced costs through improved production efficiencies and reducing the need for skilled labour Improved motivation of workers, as tasks are not so mundane Involves workers http://www.youtube.com/watch?v=FG3mMQ_n3w4 http://www.youtube.com/watch?v=k-HbxF82nDE