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ASQ LSSGB > Waste Elimination > Flashcards

Waste Elimination Flashcards

1
Q

What is 5s?

A

tool for workplace organization and standardization

sort
straighten
shine
standardize
sustain

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2
Q

What does each S mean?

A

sort - remove unneeded
straighten - arrange for ease of use
shine - cleanup campaign
standardize - maintain the system
sustain - make 5s the culture

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3
Q

What is a pull system?

A

a system for managing scheduling and material flow so that overproduction and excess inventory are eliminated

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4
Q

How does a pull system work?

A
  • synchronizes production with customer demand
  • replenishes product as it is consumed by a subsequent processing step
  • seeks to produce only the exact products needed, in the exact quantity needed, in shortest lead time possible
  • used when you want to reduce overproduction and inventory costs
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5
Q

What are the characteristics of push systems?

A
  • bases production on forecast or other mechanisms not directly linked to consumption
  • creates products that are sent when made and stored where needed
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6
Q

What are the characteristics of a pull system?

A
  • limits production to only what has been consumed
  • begins production with a pull signal
  • products are stored where they are made and pulled when needed
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7
Q

What are the consequences of a push system?

A
  • risks mismatch between supply and consumption and, consequently a shortage or excess stock (excess is more common)
  • requires less planning and guesswork to determine production plans
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8
Q

What are the consequences of a pull system?

A
  • results in match between supply and consumption
  • material shortages are very visible
  • delivers/produces in small quantities
  • makes regular review of consumption levels (correct pull levels) essential
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9
Q

What are the primary elements of a pull system?

A

1) Trigger
2) Flow
3) Upstream - ready process
4) Downstream - in-use process

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10
Q

What are types of pull systems?

A

replenishment (supermarket)
sequential
mixed pull

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11
Q

What is a replenishment (supermarket) pull system?

A
  • each process has a “store” that holds a specific amount of product it produces
  • consumption triggers replenishment
  • system carries inventory for all products
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12
Q

What is a sequential pull system?

A
  • used if holding inventory isn’t feasible
  • production is queued to control inventory
  • kanaban cards signal production
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13
Q

What is a mixed pull system?

A
  • uses replenishment (supermarket) for high volume
  • uses sequential for low volume
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14
Q

What is kanban?

A

a system that ensures that material and information move into and out of a process in a timely manner

GOAL: materials do not arrive before they are needed

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15
Q

When is kanban used?

A
  • in pull systems
  • to reduce overproduction
  • reduce work-in-progress inventory costs
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16
Q

What is standard work?

A

a method of documenting the current best practice for effectively and efficiently completing a process

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17
Q

What does standard work documentation create?

A
  • clear standards
  • consistency
  • efficiency
  • reduces variation
  • minimizes waste
18
Q

Standard work documents the ______________ best practice but it is intended to be _________________.

A

current
improved

19
Q

What are the benefits of standard work?

A

there can be no improvement where there are no standards

20
Q

What are the different time elements for measuring standard work?

A

cycle or process time = time for each step in process
lead time = total time including wait time
takt time = net time available to meet customer demand

21
Q

What is the takt time formula?

A

T = Ta/D

T = product assembly time required to meet demand
Ta = net time available to work
D = customer demand

22
Q

What is the formula for cycle time?

A

=net production time/number of units produced

23
Q

What is the lead time formula?

A

= order delivered - order received

24
Q

Standard Work In Progress (SWIP) tells us…

A
  • if we are meeting SWIP target, process is flowing
  • if # of products > SWIP, there is a bottleneck
  • if # of products < SWIP, process is performing better than expected, insufficient products scheduled, or market demand has decreased
25
Q

What is a standard work chart?

A

a graphical view of the work cell, the path of the operator and the amount of standard WIP required to keep the process running smoothly

26
Q

What is the standard work combination table?

A

shows what the takt time is in comparison with the cycle time of the process

27
Q

What is the production capacity worksheet?

A

takes each step and breaks it down into manual time and automated time to define the total time per unit

helps identify bottlenecks

28
Q

What is the standardized work chart?

A

a consolidated document that addresses:
- takt time
- work sequence
- standard work in process (SWIP)

29
Q

What is poka-yoke?

A

mistake proofing

a means of preventing errors from occurring through the use of physical, procedural, visual, or other forms of devices that prevent improper execution of a process step

30
Q

What is the difference between an error and a defect?

A

error = deviation from standard process
defect = product does not meet specifications or customer expectations

31
Q

What is the relationship between errors and defects?

A

defects are caused by errors but not all errors will become defects

32
Q

What are sources of error? (7)

A

1) forgetting
2) dexterity limitations
3) fatigue
4) outside distractions
5) variation in component parts
6) ineffective maintenance
7) insufficient work instructions

33
Q

What are types of error? (9)

A

1) misunderstanding
2) misidentification
3) lack of training
4) willful
5) inadvertent (fatigue or distraction)
6) slowness (delay in judgment)
7) lack of standards
8) surprise (malfunction)
9) intentional (sabotage)

34
Q

What are defects caused by errors? (6)

A
  • missed steps
  • set-up errors
  • missing parts
  • wrong part assembled
  • wrong part worked on
  • adjustment, measurement, or dimensional errors
35
Q

Remember: Everyone makes ____________. The goal is to design better _________, ______________, ____________, etc. to facilitate the ___________ or ____________ of mistakes and errors.

A

mistakes
systems, procedures, environments
reduction, elimination

36
Q

What are the characteristics of defects?

A
  • attributes by nature
  • can’t be measured; no “degree of goodness”
  • either works or doesn’t; right or wrong
  • requires functional test or visual inspection
37
Q

What are the three components of a poka-yoke device?

A
  • 100% inspection
  • rapid feedback
  • low cost and simple
38
Q

What are the two types of poka-yoke devices?

A
  • prevention devices
  • detection devices
39
Q

What are the 5 principles of mistake proofing?

A

Elimination - remove defect causes
Replacement - substitute a different process
Facilitation - put something in place to facilitate the process of producing a good end result
Detection - identify defect when it occurs
Mitigation - reduce consequences of defect

40
Q

How do you standardize?

A

1) Approach - establish a standardized approach
2) Flow - what needs to be done regularly
3) Frequency - determine how often
4) Checklists - create standard 5s checklist
5) Responsible Parties - decide who is responsible for what
6) Combine - incorporate checklist into standard work instructions

41
Q

Standards should be… (7)

A
  • concise
  • easy to understand
  • simple language (no technical jargon)
  • as visual as possible
  • comprehensive
  • reviewed and updated
  • communicated throughout

ASQ LSSGB (18 decks)

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