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5.3 Lean Production
5.3 Lean Production
3 Lean production
and quality
management
(HL)
Section 5 Operations management
Unit content
Unit Assessment objective
Features of lean production: AO1
• Less waste
• Greater efficiency
Think back to your morning routine. What are some of your mudas?
Principles of lean production
Waste minimization
• This requires the removal of any operation or process that does not
add value to the product.
‘Right first time’ approach
• Businesses aim for zero defects by identifying and resolving
problems at the source.
Flexibility
• Resources must be adaptable to changing needs of the business.
Continuous improvement
• The firm must continually strive to improve quality and efficiency.
改善
Supply chain management
• Businesses must develop and maintain good professional working
relationships in the supply chain.
Methods of lean
production and
their impact on
the organization:
Continuous improvement (kaizen)
Just-in-time (JIT)
Kanban
Andon
Lean production at Toyota
Watch this video about Toyota’s methods of lean production and answer
the following questions.
1. What is a JIT system?
2. What is kanban?
3. What is kaizen?
4. What competitive advantage did
Toyota have from its methods of
lean production?
5. Which firms adopted Toyota’s
lean production methods?
6. In which industries do these
firms belong? (You many need
to search for this information
after the video).
Continuous
improvement (kaizen)
Quality control
Quality assurance
Advantages and disadvantages of quality control (QC)
Advantages Disadvantages
• Prevents faults reaching the • It is expensive to fix
customer, thus safeguarding mistakes.
reputation.
• The root cause of the
• Cheaper to have trained QC problem is not dealt
inspectors than to train with.
every employee to be
responsible for QC. • Lack of accountability for
• Widespread issues and substandard work by
problems across the individuals.
organisation can be
identified by QC inspectors.
Advantages and disadvantages of quality assurance (QA)
Advantages
Disadvantage
• The time, energy and training needed to nurture a total quality culture
within an organization.
Methods of
managing
quality and their
impact on the
organization:
Quality circles
Benchmarking
Total quality management (TQM)
• These are small groups of people who meet regularly to examine
issues relating to the quality of output and make
recommendations for improvement.
Quality circles • Quality circles are like kaizen groups. However, the key
difference is members of quality circles also execute and
manage solutions to quality issues.
Benefits Drawbacks
Improved Not all
efficiency, employees enjoy
production, this form of
profitability empowerment
and and would rather
motivation. be told what to
do.
Benchmarking
https://www.iso.org
Lean production and quality management and
CUEGIS
• Although lean production and • This strategic approach to
quality is often associated with service delivery helps to
manufacturing, the principles of improve the quality of a hotel
lean production can be applied experience while enjoying cost
to services. savings from the reduction of
wastage.
• Many Japanese hotels have
implemented a lean approach
to the process and physical
evidence aspects of a hotel
experience.