Basics Chapter 4-7 Flashcards
Jidoka - Principle
Autonomation - Flexibility of worker & automation of machine
• More flexibility to the production system through automation with a worker’s intelligence.
Eg: Using light signals when problems occur and then abort operation at once.
• Occurances of problems can also improve the quality, customer service and the cost and the lead time by stopping the processes.
Jidoka - 5 Advantages
- Effective use of manpower
- Improve process quality
- improved level of customer satisfaction
- Quality consciousness of employees
- Lower costs
Poke Yoke
Mistake prevention techniques
• Soft: Visual prevention => OPL
• Hard: Mistakes can not be comitted (different power sockets / geometry of USB)
• Bar Codes and Colour Coding
Andon
Mistake prevention techniques
• display the present condition of the production line to the employee by using light signals (g: good, y: help, r: stop)
• Notification of defects/problems; Warning for employees
LCA - Philosophies
- Increasing flexibility of automated processes as well as decreasing the expenses.
- Employee’s manual work can be supported by easy and reliable devices and by utilising the gravitational law.
- Low investments in case of future changes
- Ease employees tasks through ergonomics
LCA - Support of manual work through Tools
- Springs
- Storages
- Utilisation of gravity
- tilting mechanisms
- Bionic handling assistance
Technology Oriented Production - Characteristics
- Production in Badges - delivered, processed and next
- Optimum Badge Size - Optimised setup times and min. storage costs
- Optimum Utilisation of machine - Badge production in sequence for optimal utilisation
- Optimization of processing times - each machine optimized to process badge as fast as possible
Technology Oriented Production - Disadvantages
Long throughput times
• Waiting time at each single station
• Set-up times between different badges
• Transport time through long distances
High Inventories
• Large Buffers before and behind machines
• Products in stock - one badge is not completely deliverd at once
Vulnerability to Serial defects
• badge often produced without inspectation
Process Oriented Production (Lean Production) - Characteristics
- Prod. control based on market demands
- Arrangement of machines throughout production process
- Production in takt of customer
- One piece flow
- Smoothend and leveled production
- Optimized set up times
Takt Time - definition & formula
Time between the completion of previous and subsequent product.
=/= Troughput Time - Completion of product from scrap
• Determined by customer demand
• synchronises all work stations - no waiting
• TT = daily Available production time / required units per day
Total Quality Management - Characteristics
- Participation of all involved Persons (Employees, suppliers, customers)
- Quality of all required elements is of concern (Product, Services, Processes)
- Corporate Policy oriented towards quality (employee training, management decisions)
=> Continuous process
