Ch 6: Manufacturing Processes

For make to stock products, an essential issue on satisfying customers is to balance the level of ______________________ against the level of customer service.

inventory

Little's law states that ________________ = throughput rate x flow time

inventory

Boeing's process for making commercial aircraft is an an example of these two manufacturing processes:

make-to-order and engineer-to-order

a map showing the flow of materials through a manufacturing system is know as a _____________________________ process map.

make-to-stock

assemble-to-order firms combine a number of _______________________ to meet a customer's specifications.

pre-assembled modules

make-to-order firms make the customer's product from ________________________________.

raw materials, parts and components

A ______________________ layout solves the problem of "birdcaged" operators with no opportunity to share work or add another operator.

Flexible line

A __________________________ layout solves the problem that a straight line is difficult to balance the flow of work. For example, a U-shaped line gives better operator access and may reduce bottlenecks or the need for operators.

Flexible line

A___________________ layout removes barriers to operators so work can be shared and operators can be added or removed as needed.

Flexible line

_____________________ layouts solve the problem of operators trapped in "cages", which prevents sharing work among them.

Flexible line

With _________________________ development, machines and associated processes are typically regrouped into families of parts or families of equipment.

Manufacturing cell

_____________________________ development deals with grouping parts into families that follow a common sequence of steps.

Manufacturing cell

______________________________ development identifies dominant flow patters for each part family.

Manufacturing cell

_____________________ process is used for manufacturing items such as liquids, chemicals and drugs.

continuous

Assembly lines and ____________________________ production system designs are for the special purpose of building a product by going through a series of progressive steps.

continuous layout

Highly automated machines that may operate 24 hours a day are characteristics of a _______________________ line.

continuous process

______________________ is used to avoid expensive shutdowns by operating 24 hours a day.

continuous process

True or false: Total average inventory is the best measure of inventory.

false

make-to-stock firms serve customers "on demand" from _____________________.

finished goods inventory

The time between successive units coming off the end of an assembly line is referred to as _____________________.

workstation cycle time

When parts are moved on a conveyor that passes a series of workstations in a uniform time interval, this is called the ____________________.

workstation cycle time

Products that are customized only at the very end of the manufacturing process.

Assemble to Order (ATO)

______________________ measures how long (on average) a firm's inventory can support sales.

Days-of-supply

List the different product classifications in order of low to high inventory investment:

ETO, MTO, ATO, MTS

List the different product classifications in order of where the customer decoupling point (where the inventory is positioned) along the supply chain:

ETO, MTO, ATO, MTS

unique, customized products

Engineer to Order (ETO)

_______________________ compares cost of goods sold to average inventory.

Inventory turn

the long-term relationship between inventory, throughput and flow time is mathematically related using ______________________'s law

Little

List the different product classifications in order of short to long customer lead times:

MTS, ATO, MTO, ETO

products that have similar designs but are customized during production

Make to Order (MTO)

Products that require no customization

Products that require no customization Make to Stock (MTS)

lean manufacturing

a means of achieving high levels of customer service with minimal inventory investment

Total work at a station is equal to the sum of ______________________________.

all tasks assigned to that station

For ____________________________ companies, there are significant advantages from moving the customer order decoupling point from finished goods to components.

assemble-to order

A primary task for _____________________________ firms is to define a customer's order in terms of alternative components since these are carried in inventory.

assemble-to-order

Dell Computer, who make desktop computers from a variety of finished goods components, is an example of a __________________________ company.

assemble-to-order

One capability required of __________________________ products is a design that enables as much flexibility as possible in combining components.

assemble-to-order

Which layout moves product from workstation to workstation at a controlled rate?

assembly line

________________________ is the project layout for items produced through a fixed sequence of workstations.

assembly line

Days-of-Supply

average inventory/cost of goods sold x 365

Inventory turn is calculated by dividing ____________________________ by average inventory value.

cost of goods sold

Inventory Turnover

cost of goods sold/average inventory

With a combination of make-to-order and engineer-to-order manufacturing processes, ___________________________ could be in either raw materials at the manufacturing site or the supplier inventory.

customer order decoupling point

= 1 / inventory turn x 365

days-of-supply

= average inventory / cost of goods sold x 365

days-of-supply

engineer-to-order firms work with the customer to ________________________________.

design and make the product

= sum of task times / (actual number of work stations x cycle time)

efficiency

True or false: Inventory turn and days-of-supply are unrelated measures.

false

Make-to-stock firms use ________________________ to achieve higher service levels for a given inventory investment.

lean manufacturing

Televisions, clothing, packaged food products are examples of _____________________________ products.

make to stock

A ________________________ is generally made up of dissimilar machines, set up by family, and grouped into cells.

manufacturing cell

A _________________________ is formed by allocating dissimilar machines to cells that are designed to work on similar products (shape, processing, etc.)

manufacturing cell

A _________________________ uses a flexible sequence of workstations.

manufacturing cell

If inventory turn is known, days-of-supply is calculated by

multiplying the inverse of inventory turn (1/inventory turn) by 365

workcenters are often structured to _________________ the movement of material

optimize

The ____________________ relationship identifies the restrictions imposed by product design and. process technologies.

precedence

The __________________________ relationship identifies the restrictions imposed by product design and process technologies.

precedence

On an assembly line, the order in which tasks must be performed is called the ___________________________.

precedence relationship

The ________________________ matrix has two dimensions: product volume and product standardization.

product-process

The __________________________ matrix depicts when the different production process types are typically used depending on volume and standardization.

product-process

A ____________________ is used for large projects in a specific location, such as a house or bridge.

project layout

In ______________________ layout, the product remains in one place while resources travel to the product as needed.

project layout

_____________________ techniques are typically used to manage production processes that follow a project layout structure.

project management

List the production processes from lowest to highest-volume

project, workcenter, manufacturing cell, assembly line

3 steps of the manufacturing process: 1) _____________ the parts needed 2) _____________ the product 3) _____________ the product

source, make, deliver

Reducing Task Time Requirements: _______ the task _______ the task Use _________________ Use a ________________ Work ______________ re-________________

split share parallel workstations more skilled worker overtime design

Total average value of inventory

the sum of the value (at cost) of the raw material, work-in process, and finished goods inventory

lead time

the time needed to respond to a customer order

is the sum of raw material, work-in-process, and finished goods inventory.

total average value of inventory

customer order decoupling point

where inventory is positioned to allow entities in the supply chain to operate independently

In a _____________________ layout, machines are grouped according to type or function and parts travel to the appropriate location for processing.

workcenter

A __________________ is generally used for low-volume systems that produce a variety of products.

workcenter layout

___________________ are often focused on a single type of operation.

workcenters

= production time per day / required output per day in units

workstation cycle time