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OPMTChap015st - Chapter 15 Lean Operations CHAPTER 15 LEAN...

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Chapter 15 - Lean Operations CHAPTER 15: LEAN OPERATIONS Answers to Discussion and Review Questions 1. Reduce downtime due to changeovers by reducing changeover time: JIT concentrates on reduction on setup times so that the lot size can be reduced. Of course, reduction of the lot size will result in reduction of the inventories and also increase productive time as a result of less time being allocated to changeovers. This approach is different than the traditional manufacturing approach where the main goal is to balance the trade-off between the changeover (setup) cost and cost of carrying inventory. Use preventive maintenance on key equipment to reduce breakdowns and downtime: Utilization of preventive maintenance can reduce breakdowns and downtime. Even though preventive maintenance is also part of traditional manufacturing systems, the manufacturing systems utilizing JIT will spend more money to ensure that breakdowns are avoided so that downtime is not experienced. Avoiding downtime will enable the company to reduce work- in-process (WIP) inventories because since we are not concerned about breakdowns, we do not need to maintain as much WIP, leading to reduced inventories and reduced waste. Cross train workers so they can help when bottlenecks occur or other workers are absent. Train workers to handle equipment adjustments and minor repairs: The name of the game is flexibility. Cross-training workers to handle different tasks will improve the flexibility of the system. The added flexibility will assist the company in a wide variety of ways. For example, if the cross-trained worker can assist a bottleneck work center, then the system throughput will increase and the work-in-process inventories can be reduced. If the trained workers can handle the minor repairs, then the repair crew does not have to be called. The ability of the worker to fix the equipment on-line not only improves the efficiency, but also reduces potential inventory buildup and saves the cost of the repair crew fixing the machine.
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