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Lean > Exam 1 > Flashcards

Exam 1 Flashcards

1
Q

When should you use a histogram?

A

when you want to see shape, spread, and frequency

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2
Q

When should you use a check sheet?

A

when you want to collect data about a process under investigation, use to tally issues

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3
Q

When should you use a pareto chart?

A

when analyzing data about the frequency of problems or causes in a process, 80/20 rule,

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4
Q

When should you use a fishbone diagram?

A

when attempting to identify the root cause of the problem, focuses on the problem not symptoms

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5
Q

When should you use a defect concentration map?

A

when trying to identify a process that cuases the defects, uses a picture of the product to show the location of the defects

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6
Q

When should you use a scatter plot?

A

useful for identifying a relationship between two continuous variables, shows how much one variable affects another, shape indicates relationship

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7
Q

When should you use a control chart?

A

tracks process over time, identifies between special and common cause variation

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8
Q

What is a XMR chart?

A

x and moving range chart based on the avg moving range, answers: is the process stable over time? How capable is the process? What is the effect of a process change on the average or range?

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9
Q

What is a p chart?

A

used to chart the percentage defective when the sample size is greater than 50, for variable or constant, binomial

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10
Q

What is a np chart?

A

used to chart the number of defective units when the subgroup size is constant, usually greater than 50, binomial

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11
Q

What is a c chart?

A

used to chart the number of defects when the subgroup size is constant, usually greater than 50, poisson distribution

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12
Q

What is a u chart?

A

used to chart the number of defects per unit when the subgroup or constant, poisson distribution

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13
Q

Describe the A3 process

A 
background 
current conditions 
goals / targets 
analysis 
proposed countermeasure 
plan
followup
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14
Q

What is the equation for percent rhtym time?

A

sum of C/O + sum of run times

availble time

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15
Q

What is an ideal rhythm percentage?

A

85%

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16
Q

What is the equation for inventory replenishment levels?

A

Rhythm demand (rhythm time * avg demand) + SS stock demand variability (z*std dev of demand * sqrt repT)+ safety stock supply variability ( z * std dev of supply * sqrt of Rept) + other cycle time demand ( other cycle time * average demand)

17
Q

What is the equation for kanban?

A

Repd ( replenishment time * avg demand)+ safety stock demand variability (Z x STDdx Sqrt(RepT) + safety stock variability ( x STDs x Sqrt(RepT)

18
Q

What are the out of control situations?

A

if 2/3 sucessive points fall in the area beyond 2 standard deviations from the mean either above or below
if 4/5 successive points fall in the area that is beyond one standard deviation from the mean, either above or below
if there is a run of 6 or more points that are all either succesviley higher or lower
if 8 or more points fall on either side of the mean
if 15 points in a row fall within the area on either side of the mean that is one standard deviation from the mean

19
Q

What are the levels of the lean hierarchy?

A 
MTO - pull 
MTO - push / pull (postponement)
inventory as a control point (pull)
Inventory as a control point (push / pull)
MT Forecast - push/pull
MT Forecast - push
20
Q

What are the 8 questions when developing a future state VSM?

A

What is the takt time?
Will you build to the finished goods supermarket?
Where can you use continuous flow?
Where will you need to use a supermarket pull system?
Where will you schedule production pacemaker?
How will you level load the production mix?
What is your pitch?
What process improvements will be necessary to implement your future state VSM?

21
Q

What is takt time? (equation)

A

Availble working time

customer demand

22
Q

What is pitch?

A

takt time * packout quantity

23
Q

What did Donnelly want to do to improve their current state?

A

switch to a true kanban system
reduce changeover time in the paint booth
smaller paint booths dedicated to families

24
Q

What is little’s law?

A

If I have x amount of inventory, how much time does that equate to?

25
Q

What is the equation for little’s law?

A

time = inventory

rate

26
Q

What is takt time?

A

the max acceptable time to meet the needs of the customer

27
Q

What is the total work content?

A

time to process the product

28
Q

What is the planned cycle time?

A

how long it takes to make just one product

29
Q

What is percent rhythm time?

A

Sum C/O + Sum of Run Times

Available time

30
Q

How do you determine how many employees are needed in a production cell?

A

number of associates = twc / pct

31
Q

What are the 7 forms of waste?

A 
DOWNTIME 
Defect 
Overproduction 
Waiting 
Non utilization 
Transportation 
Inventory Excess 
Motion waste
Excess Processing
32
Q

What is the equation for avg inventory?

A

IRL - 1/2 rhythm demand

33
Q

What is the equation for replenishment time?

A

rhythm time * other cycle time

Lean (1 decks)

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