Second Partial Exam

Question 1

What is a Control Plan

Answer 1

A tool that generates the strategies for the monitoring and corrective action application to the process after the FMEA.

Question 2

Whats to be done after the control plan is finished

Answer 2

It need to be communicated to the users

Question 3

Mention Tips for staying Lean

Answer 3

• Lean is a philosophy for success not just tools
• Apply it across the whole organization.
• Improve processes not departments
• Dont copy from other organizations

Question 4

5 basic tips of lean

Answer 4

• 5 S system
• Total productive maintenance
• Continuous flow
• Jidoka (automation)
• SMED

Question 5

Goal of the TPS

Answer 5

Highest Quality & lowest cost, /short Lead time

Question 6

Involvement

Answer 6

Team members continually seeking better ways

Question 7

Lean Manufacturing Activities

Answer 7

Hoshing planning, Takt Time, Heijunka

Question 8

JIT activities

Answer 8

Pull system, Takt time, Kanban, Involvement

Question 9

Jidoka Activities

Answer 9

Poka-Yoke, Control, Visual order

Question 10

Characteristics of Standarized Wor input

Answer 10

People, Machines, Material, Method

Question 11

Characteristics of standarized work output

Answer 11

Productivity, Quality, Cost, Delivery time.

Question 12

Labor density

Answer 12

Labor Density= Work (demand)/motion

Question 13

Prerequisites For standarized work. SOURCES OF INESTABILITY

Answer 13

-Quality Problems with incoming parts, problems with tools and machines, safety problemas, Part Shortages

Question 14

ELEMENTS OF STANDARIZED WORK

Answer 14

Takt Time
Work Sequence
In process stock

Question 15

Cycle time

Answer 15

Actual time it takes to do the process

Question 16

Takt time

Answer 16

Daily operating time / required quantity

Question 17

Work Sequence

Answer 17

Defines the order in which the work is done in a process

Question 18

In process stock

Answer 18

The minimum number of unfinished work pieces required for the operator to complete the process.

Question 19

Formula for capacity

Answer 19

Operational time per shift / (Process time + setup time / interval)

Question 20

Goal for standarized work

Answer 20

Kaizen

Question 21

Production Kanban

Answer 21

The kind and quantity of product that the upstream process ( supplier must produce)

Question 22

Withdrawal Kanban

Answer 22

The kind and Quantityof product the downstream process may withdraw

Question 23

Kanban Rules

Answer 23

1- Never ship defective units
2- Customer Withdrawal only what is needed
3- Produce the quantity withdrawn by the customer
4- level production
5- Stabilize and strengthen the process

Question 24

Kanban Formula

Answer 24

Qtty of parts = demand quantity per day * (order interval + production lead time) + safety inventory

Question 25

What processes uses kanban thinking

Answer 25

Any process