Module 2 - Process Mapping & Lean Methods Flashcards
Mass Production is a term used to describe a system of manufacturing that takes advantage of ___ __ ___.
AKA ___ & ____
Lead time is _____.
economies of scale.
AKA batch & queue
Lead time is long.
Mass production is associated with push or pull systems?
Push systems because the decisions need to be made far ahead of time
Mass production systems should be when:
– demand forecasts have (low/high forecast errors?
–manufacturing setup costs are (low/high)?
–resource (particularly labor) costs are (low/high)?
Mass production systems work best when demand forecasts have low forecast errors, manufacturing setup costs are high, or resource (particularly labor) costs are high
Lean Production refers to a production system that seeks to _____ _____ during the production of goods and services.
AKA ___.
Lead time is ___.
eliminate waste
TPS - Toyota Production System
Lead time is short.
What is JIT and what does it stand for?
Which production system is it associated with? Is it typical a push or pull system?
Just-in-time - production is synchronized with demand
Lean (TPS)
Pull system
Describe pull system
products are moved based on actual customer demand
Push system - products are moved based on _____ customer demand
forecasted
What is the five step process for applying Lean to a production operation?
- Specify value (from each customer’s perspective).
- Map the value stream (i.e., the flow of products).
- Optimize product flow (by removing waste to minimize interruptions in flow).
- Establish pull system (so that work can be synchronized with customer demand).
- Strive for perfection (where the goal is zero waste).
Value stream map is used for what? What is it a part of? What is it?
The second step in the lean process analysis. It’s a pictorial representation of the current process. Used for analyzing the current process and designing a future process.
The swim lane structure is particularly important because….?
… many problems occur with the handoff of information across functional boundaries.
Best-case flow time (called the theoretical flow time) will be much less than the flow times experienced in reality. Give an example.
Although the time the technician takes to repair your bicycle may be 30 minutes, the shop will typically ask you to leave your bicycle for several hours or overnight. Many reasons exist for the gap between the theoretical flow time (30 minutes) and the actual flow time (say, 1 day). Examples include other bicycles in queue waiting for repair, inability of the technician to find or obtain necessary parts, and readjustments that may be necessary to get the brakes “right.”
Define value-added activities
Activities for which customers are willing to pay
Lean practitioners often use the Japanese term ____ when referring to a wasteful activity.
What are the two groups?
Muda
(a) Type I muda – wasteful activities that are currently necessary
(b) Type II muda – wasteful activities that are absolutely unnecessary
The long lead time that characterizes mass production systems is dominated by muda (transportation, machine setup, waiting in queue, etc.).
Name the 7 wastes that apply to manufacturing
Waiting
Inventory
Defects
Motion
Over-Processing
Overproduction
Transportation
A Kaizen Event is a ….. designed to…?
Translated as…?
When a team will be formed and a focused one- to five-day effort will ensue called kaizen event. Designed to support an effective, short-term brainstorming session that focuses on a single challenge and improves an existing process.
The term is loosely translated from the Japanese to “change for the good.”
Categorize the following service-related wasteful activities:
(a) an accountant verifying a financial calculation,
(b) an engineer creating PowerPoint slides,
(c) a technician resolving a customer complaint,
(d) a clerk entering data,
(e) a customer waiting in line at a bank
(i) walking to the copier
(a) over-processing,
(b) over-processing,
(c) defects,
(d) over-processing,
(e) waiting
(i) motion
Describe a Fishbone Diagram.
What is used for categorization?
documents all potential causes of a problem that are known by a project team, organized in a hierarchical format.
Some analysts use the “6 M’s” as a form of categorization: Man, Machines, Measurements, Methods, Materials, and Milieu (or Management)
Check sheet
keeps track of things (ie- types of issues) using tally markers
Pareto Chart. Describe it. Why is it useful to à team?
shows how minority of possible causes could be responsible for a high majority of the impacts of problems.
(Histogram w line over it).
The Pareto chart is useful because it prevents a project team from solving problem that have minor impacts on customers
Adding a trend line to every scatterplot is a good idea. True/False?
False. It can bias a viewer by implying
(a) a relationship between the two variables exists, and
(b) that the relationship is liner.
Service processes share a number of common structural characteristics. Which 6 are not be found to the same extent in manufacturing?
(a) main flow unit is information,
(b) significant task variability,
(c) cross-functional process flows,
(d) many handoffs of information,
(e) hidden benefits and costs, and
(f) no explicit motivation for urgency.
Developing the standard work method in Lean is the responsibility of _____.
What does it prescribe?
the employees, NOT the managers
It prescribes how process activities are accomplished (ie: documentation)
What does SMED stand for?
It’s made to reduce what?
Describe external vs internal implementation?
Single-Minute Exchange of Dies.
–lean methods for reducing the time it takes to setup/chance equipment; to reduce long manufacturing setup times to less than 10 minutes
–“externally” (i.e., while the process is working on the prior task) and “internally” (wasteful)
Poka-yoke
Mistake-proofing
– used to develop processes that cannot be done incorrectly
