14. Process Characteristics Flashcards
Process Flow Metrics P. 205
- WIP
- WIQ
- Touch time
- Takt time
- Cycle time
- Throughput
- Value added activity
- Setup time
Work in Progress (WIP)
Material between input and output (finished) stage.
Asset and Liability.
Work in Queue (WIQ)
Material waiting to be processed. One component of WIP.
Touch time
Time of a unit of product is actually being worked on.
Takt time
Rate in time per unit at which the process must complete units in order to achieve the customer demand.
Time per unit:
Time available / # units to be produced
Unit per time: # units to be produced / Time available
Cycle time
Time required to complete one unit form the beginning of the process to the end of the process.
Throughput
Amount of output that passes through the process in a specified period of time.
Setup time
Time from the last unit on one job to the fist good unit of the next job.
Hidden Factory P. 208
The collection of activities in a process that generate waste (loss time, money, and effort).
Process Analysis Tools
- Flowcharts
- Process Maps
- Value Stream Maps
- Work Instructions
- Spaghetti Diagrams
- Circle Diagrams
- Gemba Walk
Flowcharts P. 209
Pictorial or graphical representation of a process.
- Define the process
- Define the boundaries
- Determine the level of detail
- Brainstorm the activities that take place
- Arrange proper sequence
- Draw arrows to show flow
- Review with other to seek agreement
Process Maps P. 211
Concept of Y= f(X). Basic anatomy:
- Input variables (X). Below the flow line.
- Desired output. Above the flow line.
Input Variables (6 M’s) P. 213
- Machines (Equipment)
- Manpower (People)
- Materials
- Measurement
- Methods (Process)
- Mather Nature (Environment)
Input Variables Classification P. 214
C- controllable
N- noise (too expensive or uncontrollable)
SOP- predefined way of a process (C)
X- Critical subset of controllable variables
Value Stream Map P. 217
Future State:
- Produce to the takt time.
- Create continuous flow wherever possible.
- Use supermarket pull systems to control production where continuous flow does not extend upstream.
- Send the customer schedule to only one production process (the pacemaker process).
- Level the product/service mix evenly over time at the pacemaker process.
- Level the production volume by creating an “initial pull,” releasing and withdrawing small, consistent increments of work at the pacemaker process.
- Develop the ability to make “every part every day” in processes upstream of the pacemaker process.
