Operations Managemen (Absolute Memorization) Flashcards
History of Manufacturing Management.
Interchaangeable Parts
Frederik Tailor (Standardize work, Time&Study)
Process Charts, Motion Study
Henry Ford (Assembly Lines, Flow Lines, Manufacturing Strategy)
Quality Gurus (Statistical Process Control, TQM)
Toyota: (Just in Time, Stockless Production, World Class Manufacturing)
Scientific Management (Principles to Increase Efficiency)
STUDY
STANDARDIZE
SPECIALIZE
PERFORMANCE AND PAYMENT SYSTEM
Scientific Management (Implementation Problem)
Unshare performance gains More work same pay Monotonous work No Knowledge tranfer Rules to discourage high performance
Henry Ford
Assembly Lines
“Take the wok to the man not the man to the work”
“ A customer can have any color he likes for its car as long as its black”
The prosperity Cycles
What are and Explain the Elements of Just in Time Production
Tackt Time
Flow Production
Pull System
What are the 7 Types of Waste
Over-Production Wait Time Transportation Processing Inventory Motion Defects
What is continuous Flow Production
Lowering Inventory Reduces Waste (Unireliable Vendors, Scrap, Capacity inbalances)
What Implications have lower inventories
Lot Size (Inventory Cost, Setup Cost)
Reduce Set Up Cost
Quick Set Up
SMED (Single Minute Exchange of Dides)
Explain the Components of SMED
Internal Set Up
External Set Up
Describe the Principles of the Toyota Production System *Toyota House
Goal: Highest Quality, Lower Cost, Shortest Lead TIme
Just in Time: Continuous Flow, Tack Time, Pull Suste,
Jidoka: Autonomation,
Base. Heijunka, Standard Work, Kaizen
What is the Toyota’s Phylosophy
Toyota’s philosophy
• Selling price – Cost = Profit
• Customers decide the selling price.
• Profit is what remains after subtracting the cost from it.
• The main way to increase profit is to reduce cost.
• Consequently, cost reduction through waste elimination
should have the highest priority.
• Toyota’s paradox: Reducing cost (waste), will reduce lead
time while increasing quality and customer satisfaction.
• How? We will discuss it soon.
Jidoka Techniques
• Poka-yoke (mistake or error proofing)
– A form of device for building-in quality at each production process.
– This device may take many shapes and designs.
– Typical types of Pokayoke are sensors, proximity switches, stencils, light guards and alignment pins.
Simple circuitry is usually used to operate these electrical error proof devices as they should be of low cost and simple design.
– Goal: Finding defects before they occur = Zero Defects
– Statistical Quality Control (SQC): Finding defects after they occur
• Visual management including using Andon Lamp
Explain 5’s
– Seiri - keep only what is absolutely necessary, get rid of things that you don’t need, i.e. simplify or sort. SORT
– Seiton - create a location for everything, i.e. organize
or straighten. STRAIIGHTEN
– Seiso - clean everything and keep it clean, i.e. cleanliness or sweep. SWEEP
– Seiketsu - implement Seiri, Seiton and Seiso plant wide, i.e. standardize. STANDARDIZEE
– Shitsuke - assure that everyone continues to follow the rules of 5S,i.e. stick to it or SELF-DISCIPLINE
Why variability ocurrs?
- Employees, machines, and suppliers produce units that do not conform to standards, are late, or are not the proper quantity
- Engineering drawings or specifications are inaccurate
- Production personnel try to produce before drawings or specifications are complete
- Customer demands are unknown
What are the Five Steps of Lean Production?
- Specify Value
- Value Stream Mapping
- Create Continuous Flow
- Create Pull Production
- Perfection
