Continuous Flow Flashcards
a Lean method that allows you to move a single product through every step of your process instead of grouping work items into batches
Continuous Flow
erms One piece flow Value Stream and perspective of the customer Value Added, Business Added Eliminate everything else (waste) Work in Place Inventory (WIP)
Working on one produce at a time (or batch size of one)
Single Piece Flow
Creating a group of items before moving the group to the next step in production.
Batching
An escalator is an example of _____.
a.) Single Piece Flow
b.) Batching
a.) Single Piece Flow
An elevator is an example of _____.
a.) Single Piece Flow
b.) Batching
b.) Batching
Documents requiring leadership approval are collected and reviewed once each day/week is an example of _____.
a.) Single Piece Flow
b.) Batching
b.) Batching
Documents requiring leadership approval are reviewed as they arrive is an example of _____.
a.) Single Piece Flow
b.) Batching
a.) Single Piece Flow
What are some effects of decreasing batch size?
Increase response to the customer
Reduce waiting (time in queue)
Decrease lead time
Reduce dependency on forecasting
Reduce inventory
Enhance flow
Below describes a Push System or a Pull System?
*Based on forecasts or schedules
*Disregards subsequent process steps
High inventoryPoor communication
*Anticipates usage
*Waste (large lots, inventory)
*Propagates errors
Push System
Below describes a Push System or a Pull System?
*Response to customer demand
*Pulls from previous operations
*Just in time
*Good communication
*Actual consumption
*Small lots
*Reduces errors
Pull System
What are some aspects of a Pull System?
1) Are flexible and simple
2) Include triggers for work to be done
3) Link work cells together
4) Are executed automatically
M_____ + M_____ = M_____
Maps + Measures = Metrics
Universal Metric that can be used in any value stream…
Processing Time ÷ Lead Time
Process Cycle Efficiency (PCE)
Throughput = WIP / cycle time
Little’s Law
A unit or a machine that uses the highest percentageof its full capacity, or is fully utilized, can create a bottleneck in the process
Full Capacity Utilization
Earliest step where WIP inventory gathers
Bottleneck
Low WIP inventory gathering
Continuous Flow
Kanban, Yamazumi, and Swim lanes are tools to identify what?
A bottleneck
in Japanese means “to stack up”; line-balancing
Yamazumi
Where can you find the bottleneck of a process?
a)The first process step
b)The process step that takes the longest
c)The process step with the most inventory
d)The first process step exceeding Takt Time
d)The first process step exceeding Takt Time
Which term most closely describes a “bottleneck”?
a)Inventory
b)Defect
c)Constraint
d)Jidoka
c) Constraint
Various tools could be used in order to identify the Bottleneck of a process. Which of the following is most appropriate?
a)Spaghetti Diagram
b)Yamazumior Line Balancing Diagram
c)Time and motion studies (measured observations of workers activities)
d)Instant observations (on a representative sample) of the operational statistics of a workstation
b) Yamazumior Line Balancing Diagram
How can you see the Bottleneck of a process?
a)The step with the most inventory
b)The earliest step where WIP inventory gathers
c)The step with a steady amount of inventory
d)The step with no inventory
b) The earliest step where WIP inventory gathers
