Unit R014 - Engineering Manufacture - Topic Area 4 - Retrieval B

Lean Manufacturing

Lean manufacturing is a business ethos (model). What is its primary aim?

• To make the products lighter.

• To encourage the production staff to eat healthily.

• To scale down production.

• To reduce waste throughout the manufacturing process.

Lean Manufacturing

The acronym TIMWOOD is used to remember the seven categories of waste that manufacturing companies aim to eliminate. What does the "T" stand for?

• Transportation

• Time

• Tools

• Training

Lean Manufacturing

The acronym TIMWOOD is used to remember the seven categories of waste that manufacturing companies aim to eliminate. What does the "I" stand for?

• Inventory

• Intent

• Industry

• Individual

Lean Manufacturing

The acronym TIMWOOD is used to remember the seven categories of waste that manufacturing companies aim to eliminate. What does the "M" stand for?

• Motion

• Machine

• Manual

• Miller

Answer explanation

Movement is also sometimes used for the "M". It still has the same meaning however.

Lean Manufacturing

The acronym TIMWOOD is used to remember the seven categories of waste that manufacturing companies aim to eliminate. What does the "W" stand for?

• Waste

• Waiting

• Workload

• Worker

Answer explanation

Movement is also sometimes used for the "M". It still has the same meaning however.

Lean Manufacturing

The acronym TIMWOOD is used to remember the seven categories of waste that manufacturing companies aim to eliminate. What does the "O" stand for?

• Order

• Over Production

• Over Thinking

• O-Ring

Answer explanation

Movement is also sometimes used for the "M". It still has the same meaning however.

Lean Manufacturing

The acronym TIMWOOD is used to remember the seven categories of waste that manufacturing companies aim to eliminate. What does the "O" stand for?

• Ordinary

• Over Processing

• Over Enthusiastic

• Original

Answer explanation

Movement is also sometimes used for the "M". It still has the same meaning however.

Lean Manufacturing

The acronym TIMWOOD is used to remember the seven categories of waste that manufacturing companies aim to eliminate. What does the "D" stand for?

• Danger

• Duplicates

• Drastic

• Defects

Answer explanation

Movement is also sometimes used for the "M". It still has the same meaning however.

Lean Manufacturing

Watch this simple production line animation. What wastes are being generated?

• Over Production

• Movement

• Defects

• Transportation

Answer explanation

In the example here there is only "value added" when the engineer fits the pyramid to the square.

The process has been made slightly better from the clip in the question as the engineer no longer has to walk over to the conveyor belt.

However there is still excessive movement of the staff member and the pyramid has to be transported to the squares.

A fully lean process would use an automated technique to lower the pyramids onto the squares.

Lean Manufacturing

This image shows the engine production line at Toyota. The tooling required is all over head on retractable cables and within easy reach for the engineers. Which waste is this aimed at preventing?

• Over processing

• Motion

• Over production

• Inventory

Answer explanation

Imagine the staff being given something like this.

Roughly the staff on a production line such as this will have 40-60 seconds to complete there task before the next product arrives.

If the tools were poorly organised this could lead to excessive motion waste as the staff would need to be moving around to try and find what they need.