Chapter 3.4 Flashcards
Name the two key ways to review and enhance specifications
- mandating the use of standardised products or services wherever possible
- Using techniques such as value analysis and value engineering to ensure that users receive the highest levels of value and cost
Name the three levels that standardisation in product manufacture can occur
- Individual parts and components
- End products they are used in
- Processes used to make them
Name 4 benefits of standardisation
- Cost reduction
- Quality
- Flexibility
- Responsiveness
Name the 5 ways the manufacturing process changes with increased volume and variety of parts used in production
- Job shop
- Production cells
- Flexible manufacturing systems
- Mixed lines
- Dedicated lines
Explain a job shop
When a wide range of end-products each call for a different range of materials and the possible number of the end products means they are made to order as it is uneconomic to store all of them in inventory
Explain production cells
The manufacturing process is divided into small groups that make sub-assemblies that are similar in terms of the parts or equipment used
Flexible manufacturing system
Method for procuring goods that is readily adaptable to changes in the product being manufactured or the quantity being produced
Explain mixed lines
Production lines in which small quantities of different products are made with quick changeover in set-up between production runs
What three things are often referred to as batch production
Production cells
Flexible manufacturing system
Mixed lines
Explain dedicated lines
Only a small number of products are made as the set-up costs for the production line are high
What is often referred to as mass production
Dedicated lines
Name an advantage of mixed lines
It increases efficiency and reduces the amount of inventory needed to meet demand
Name a main advantage of dedicated lines
It gives a low unit cost
Name an advantage of standardising products, materials and components
Allows a larger quantity of a product to be made at a time. This has the effect of reducing the unit cost
What concept may you use when utilising standardisation in a service company
Lean
Are the concepts of lean also applicable to manufacturing organisations?
Yes
What is the Lean design about
Maximising the value that a customer receives and at the same time minimising waste in delivering that value
Name the 5 elements of lean
- identify value
- Recognise the value stream
- Create flow
- Establish pull
- Seek perfection
Name the 6 concepts of Lean
- Lead time and process speed
- Work in progress
- Delays
- Value-add and non-value add
- Process efficiency
- Waste
Define lead time
The time it takes to deliver the product or service once the order is placed
What formula shows the relationship between lead time and the drivers of lead time (Little’s law)
Lead time = amount of work in process / average completion rate
What does process efficiency measure?
The percentage of time that work spends in value-adding activities and is a key measure of any process
What is the formula for process efficiency
Process efficiency = value-add time / total lead time
What is likely if the process efficiency is less than 10%
There is a lot of waste in the process
How to define waste
Anything that adds no value in the eyes of the customer
What is the amount of waste for an activity proportional to?
The delay that it causes
What are you likely to find if a process has not been through a lean assessment?
At least 50% of the work is non-value added
Name 3 factors that contribute to the importance of a requisition
- Value
- Complexity
- Importance to the organisation or the originating department
What is the purpose of lean
To make processes faster by eliminating non-value-add activities often referred to as waste
Name the 8 types of waste
- Over-production
- Unnecessary motion
- Waiting
- Transport and handling
- Over-processing
- Inventory
- Defects
- Skills
What is the acronym for the 8 types of waste
TIMWOODS
What does TIMWOODS stand for
Transport and handling
Inventory
Motion
Waiting
Over production
Over processing
Defects
Skills
What will eliminating waste help with
Standardising processes in any service industry
Explain what a standardised product is
One for which the organisation produces no variation