Measure Phase Flashcards
key components of the measure phase
Identify Inputs, data collection, measurement system analysis MSA, process capability/stability, & outputs
techniques that can be used for inputs
x-y matrix, 5whys, fishbone diagram, FMEA
Process mapping tools
SIPOC, flowchart, flow chart, deployment flow chart
VSM Value Stream Map
putting icons together in a process flow then adding data evolving about how long it takes to do things (use when figuring out TIME)
Spaghetti diagram
step to step in a physical layout, REGARDING DISTANCE
TRUE/FALSE The fewer the step the less confusion and things that can go wrong.
TRUE
top-down flow chart (commonly used for process mapping)
selectively expanding from highest level (5-9 high level activities) keep expanding until problem is reached
Activity Diagram/Process Flowchart
captures decision points, rework looks, complexity
Deployment Flowchart is used for___
large complex processes, multiple departments, handoffs are easily illustrated
What process is important for deployment
sequence and time of processes
VSM created to identify all the activities involved in ______ the product or _____ from start to finish
producing
service
What is included in the value stream for VSM?
supplies, operations, and end customer
Data regarding what times with inventories are useful for the Value Stream Map?
Lead & processing times
Define Uptime
% of time the process can operate if product is available (max uptime is typically 95% for most machines due to variablity and delays)
Define Setup Time
time to change from one type of work to anther
Define Batch size
quantity of product worked on and moved at one time
Define Rework Rate
% of total product that does not meet the customer requirement and must be worked again
Define Scrap Rate
% of total product that does not meet the customers requirement and must be discarded
Define Defect Rate
% of total product that does not meet the customers requirement (includes scrap & rework)
Define Processing Time P/T
time the product is actually within a process being worked EX: time it takes to do something
Define Cycle Time C/T = P/T divided by # of people working in process step
how often a part or product is actually completed by a process. the processing/production rate of a process or process step. Takes into account parallel processing processing and staffing
Define Lead Times L/T
elapsed time it takes a product to move through the defined Value Stream start to finish. This includes all processing time & waiting and other Non Value Added time
Define Number of People
of people required to operate the process
Define Process Capacity
Available work time X Uptime % (divided by) Highest cycle time in process
Define Littles Law
used to estimate lead time for a process or wait time for a process step
Determine Lead Time
WIP(work in process/inventory/backlog) divided by Output Rate
Example of finding Lead Time: Output rate 30 orders/hr
Backlog: 100 orders
100 orders X 60min/200 minutes
(3) Steps to find the Process Capacity
- Find step with highest cycle time CT (Process time/#of people or orders
- Calculate Available Time
(consider the hrs per shift) - Calculate Process Capability
Value Add Flow Analysis activities (3)
Customer Value Added, Business Value Added, Non-value Added (used to identify steps in a process for which the customer is really willing to pay for and what they wont)
Objective of value add flow analysis is to ____ the hidden costs, ____ unnecessary process complexity and related errors, _____ the process cycle time, _____ capacity by better utilizing resources
Eliminate the hidden costs, reduce unnecessary process complexity and related errors, reduce the process cycle time, increase capacity by better utilizing resources
True/False
Value Added is what the customers are willing to pay for
TRUE
True/False Business Value Added is the required financial activities
TRUE
Non-Value Added NVA steps are…
Does not add value, defects, errors, omissions, preparation/setup, inspection, 8 sources of wastes
What chart can you use to summarize and display the value added/business value,& non value added
Pareto chart
The mission for Value Add Flow is to improve the process by
eliminating the NVA, Reduce BVA, and Optimize the CVA
Spaghetti Diagrams is a graphical tool used to illustrate ____ and ____
space & distance
X-Y Matrix, the X are the inputs such as
controllable inputs, procedural inputs, noise (uncontrollable factors)
The X INPUTS can be used in other methods such as…..
Fishbone diagram, Process mapping, Data analysis
Fishbone technique includes labelling material, machine, method, ______, ______, & _____.
manpower, mother nature, measurements
FMEA Stands for?
Failure Mode & Effect Analysis
What is FMEA?
a structured or qualitative risk analysis of a system, design, or process in a product or service
