2.1

2.2

2.3

The original plane experience bottlenecks are that the plane it is loaded from front to back and every person stops to load their carry-on's this makes the whole line has to stop for one person to sit down. My experience the problem of the whole time stopping for one person is fixed because the plane is loaded back to front row by row and from the window seat to the inner seat. Also, my plane design is better because my plane takes ten seconds less per person to load and pack their carry-on. This is because for the normal experience it would take 30 seconds for someone to sit down, and for my experience it would only take 20 seconds. Now ten seconds might not seem like its a lot but that ten seconds adds up to 7,000 extra minutes a day. 

2.4

CGP Grey Airplane Video:https://www.youtube.com/watch?v=oAHbLRjF0vo 

Notes: 

Video 1

Lean Toyota production system   TPS

maximize value for the customer and eliminating waste 

Wastes is any action that consumes resources without adding value to the customer

lean management (Lean manufacturing)

Defining value for the customer 

determining the value stream for each product

creating a free flow of materials and raw materials

Implementing a pull system

The basic lean manufacturing tools 

VSM (Value Stream Mapping): Identifying value, mapping how value is created, creating a pull system, and always looking for improvement. 

5S: Sort, Set in order, Shine, Standardize, and Sustain

TPM (Total Productive Maintenance) : engage all levels and functions of an organization to maximize the effectiveness of production equipment

SMED (Single-Minute Exchange of Die): To do as many steps as possible while running a part so that you can quickly change to running the next part. 

Poka-yoke: To mistake proof a process

Kaizen: Focuses on eliminating waste, improving productivity, and achieving sustained continual improvement.

TPS- 

Jidoka: Create processes with autonomous, built-in quality controls

Just-In- Time: Reduce waste and improve efficiency by ensuring that materials arrive when they are needed

Lean Concept in other sectors

-In the service sectors (lean service) 

Lean Benefits for manufacturing

Increase in efficiency  

Increase in the use of measured by OEE

Reduction of inventory in the course of production=

Reductions of the production space

Shortening the time of transition from raw material to finished product 

Exchange of dies time reduction

video 2 

standardization: 

determine of identify a standard 

Ensure everyone knows the standard

Confirm the standard is reasonable and fair 

example: red stop sign

standards are meant to be improved

and are a starting point

Video 3

cellular manufacturing: 

single piece flow

no redundant activity

video 4 

six sigma to reduce defects

reducing the defects to a small amount

Focuses on increasing quality

used for business improvement

increasing in quality 

reduced waste 

reduced cost

DMAIC (define, ensure, analyze, improve, control) 

DMADV (Define, Measure, Analyze, Design, Verify)

Video 5

Lean Culture

Lean= continuous improvement of your process + respect for people

leaders need to eliminate the 8 wastes

Eliminate fear

Go to the Gemba & provide support /coaching

video 6

ISO9000: Say how your make your product and make it how you say it

quality over quantity

quality is above everything

ISO quality insurance there are dozens of different sections for things aerospace uses AS9100

video 7

CI (Continuous improvement)

Plan-Do-Check-Act

KPI: Key Performer indicators 

Increase output

Decrease inventory 

Decrease operating expenses (don't layoff important people with skills) 

 Lean Summary:

The idea of lean is from TPS (Toyota production system) lean is to maximize value for the consumer while eliminating waste from production. Some basic lean manufacturing tools would be VSM (Value Stream Mapping) where you identify value, map out how it is created, create a pull system, and always look for improvement. The 5S's which are Sort, Set in order, Shine, Standardize, and Sustain. For sort you would get rid of what you don't need, set in order you organize what remains, Shine you clean and inspect the work area, standardize you set up systems that are the same and you maintain the first 3 S's, and Sustain you maintain a stabilized workplace though continuous improvement. TPM (Total Productive Maintenance) this is where you would engage all levels and functions of an organization to maximize the effectiveness of production equipment. SMEM (Single-Minute Exchange of Die) for this you would complete as many steps as possible while running a part so that you can quickly change to running the next part. Poka-Yoke in Japanese this term means mistake proofing and is used by any mechanism in a process that help an operator not make mistakes and defects by preventing human error as they occur. Finally Kaizen, it focuses on elimination waste, improving productivity, and achieving sustained continual improvement. TPS also made processes like Jidoka and Just-In-Time. In Jidoka you make processes with autonomous, built-in quality controls the controls mean that if anyone sees a defect in a part they can stop all production so that everyone can come over and problem solve it. Just in time reduces waste and improve efficiency by ensuring that materials arrive when they are needed meaning that when a customer orders a product the parts for that product are bought right after, this way no money is wasted on storage and because the parts are bought right then the process has to be almost perfect because if it isn't then the product won't make it on time. The Lean Benefits for manufacturing are it increases efficiency, increases the use of measured by OEE, reduces inventory, reduces production space, shortens time of transition form raw to finished product. Standardization you would first identify a standard, then ensure everyone know that standard, confirm the standard is reasonable and fair to everybody. Standards are not the end product they are just a starting point and are meant to be improved upon. Cellular manufacturing is a single piece flow and allows for there to be no redundant activity. Six sigma is used to reduce defects because it focuses on only having 6 standard defects it make you focus on increasing quality and it improves your business. It increases quality reduces waste and cost. DMAIC (Define, Ensure, Analyze, Improve, Control) is a problem solving process that is the life cycle stages for a six sigma project. Lean Culture calls for continuous improvement of your process while respecting people. ISO9000 is a way of saying how you make your product and enforcing that you make it how you say you make it. ISO calls for quality over quantity AS9100 is for aerospace.