ITP 403 - Quiz #2 Olsen

5s is...?

...a place for everything... and everything in its place...and ready for use.

What are the criteria for identifying the start and stop points for timing a changeover?

1. From last good part to first good part by a stable process 2. Finish of job > to start of next job 3. Finished production run > good parts produced by stable process

What aspects of an FMEA does poke yoke address?

1. Poka-Yoke is directly connected with the occurrence and detectability tasks of FMEA. 2. Error proofing 3. Look for potential causes of error

What are the 6 steps in a changeover improvement project?

1. Select appropriate set up to reduce 2. Observe current process 3. Separate Internal and External Activities 4. Convert Internal to External Activities 5. Reduce internal activities 6. Reduce External activities

What are the characteristics of good visual controls? Give examples.

1. easily recognizable 2. commonly known 3. links to standard processes 4. drives action example: bank teller additions line @bank •Lines on the floor signal when to add more staff •Need standard processes at teller windows to make accurate estimates

Visual controls are... (6 things)

1. efficient 2. self-explaining 3. self-regulating 4. self-ordering 5. self-improving 6. worker-managed.

What are the benefits of implementing 5S as part of a lean transformation?

1. more effectiveness (less waste) 2. increased teamwork 3. better impressions on outsiders 4. less stress

What are the 4 main benefits of visual controls?

1. reduces waste 2. drives standardization 3. improves service 4. improves communication

How does 5S link to TPM?

5S keeps things organized and in its place, reducing time wastes and stress for employees. Employees have a standard system in place with 5s, more inclined to do work without direct instructions and have more autonomy. Less stress = more effective production

How does 5s interact with a lean system?

5s is part of the kaizen process and is part of the visual management process

What are the three components of OEE? Describe each conceptually (not in an equation).

Availability: time machines are able to run/not being maintenanced Performance efficiency: gives understanding of operation rate of system Rate of quality: ratio of total parts made without defects to all things made

What wastes does each component of OEE measure? Support with examples.

Availability: waiting Performance efficiency: waiting and movement Rate of quality: defects

What is breakdown maintainence? In what situations would this be an acceptable approach?

Breakdown maintenance Take repair work beyond quick fix measures Always seek root cause Historical data

What are the "6 big losses" addressed through TPM? (available time - six big losses = effective operating time)

Breakdowns setup/adjustment idling/minor stoppages Speed Defects in process and rework Start up losses

What is takt time conceptually? Describe it in words (not an equation).

Drumbeat of customer = It is the principal that all activity within a business is synchronised by a pulse, set by the customer demand

What is planned maintenance?

Effective maintenance system, time and has to be a way of life Makes or breaks relationship between production and maintenance functions Partnership key Schedule and time require both sympathetic to production needs and effective Key elements should be "lubrication control" and "spare parts" management

Describe some examples of converting internal to external setup activities for a manufacturing process.

Ex: adding oil lines to mold in injection molding Ex: setting up the screws in holes of plate when hand drill in use Ex: pre greasing next mold when other in injection molding

Describe some examples of reducing internal setup activities for a manufacturing process.

Ex: changing bolts > functional clamp or key shaped mounting holes Ex: est standard die height,pressures, size, shape, dies, tools Parallel operations Automate Eliminate adjustments

Describe some examples of reducing external setup activities for a manufacturing process.

Ex: color/number code die storage Ex: 5S Ex: material flow racks (reduce effort and motion) Ex: determine optimal storage locations

How does human behavior play a role in poke yoke?

Human Errors(common) Forgetful Misunderstand Inexperience In hurry.overwork No standardize Tired Human error (uncommon) Lazy Disregard instructions Lack motivation

What is the difference between "incorrect process" and "process not followed from the stand point of problem and impact?

Incorrect process: Following process produces defects Change process, defects go away Generally, easiest to change Process not followed: Process hard to follow consistently Proces problem, not people problem

What is the difference between internal and external setup? Which is better? Why?

Internal activities: Must be performed while the machine/ process is stopped ex: not making parts Last good part > first good part External activities: Can be performed while machine/process runs ex: making parts

What is autonomous maintenance and why is a key component of TPM?

Operator skills development program Solves problems quickly Stops accelerated deterioration of plant and equipment Stop deterioration based failures Stabilize equipment conditions (standards) Develop training materials on how to run, operate and maintain equipment

What does OEE stand for?

Overall equipment effectiveness

What is predictive maintenance? What system elements do you need to have in place for this to be effective?

Predictive maintenance (systematic approach utilizing history and equipement condition monitoring to predict and prevent catastrophic failure/breakdown) (part of planned maintenance)

What is the difference between productive and preventative maintenance? Why is this important for someone implementing TPM to know?

Productive maintenance: Scheduled based on asset conditions maintenance of normal conditions, early discovery of abnormalities, prompt response Preventative maintenance: Scheduled more regularly

Describe a non-manufacturing situation where the SMED approach might be effectively applied.

Sales Making a breakfast burrito

What is the primary objective for scrub?

Scrub means not only the initial cleaning, but creating systems to keep the area clean

What are the types of mistake proofing? Give a good example of each.

Sequencing: Order steps >eliminate error location/size: presence/absence or size of component Weights: Inaccurate weights stops process System checks: System stop when out of spec Orientation : Part won't fit in incorrectly Counts : System counts for you

What is the primary objective for sorting?

Sorting is separating the necessary from the unnecessary

What is the primary objective for standardize?

Standardizing is locking in locations.

What is the primary objective for straighten?

Straightening is the process of finding permanent locations for items.

What is the primary objective for sustain?

Sustaining is the art of keeping the gains achieved by 5S.

What is the "10 foot, 3 second" rule?

The rule says that a person should be able to look at the visual board from 10 feet away, and should be able to discern normal from abnormal within 3 seconds, allowing the person to make a decision on what to do to return the workplace to normal conditions.

What is the difference between taking a total lead time versus a TPM approach to process improvement (Hint: We talked about the "perspective" of the analysis on the white board).

Total LT more general? KPI of efficiency TPM covers entire life of equipment and human resource

How is knowing the takt time useful for: a. Engineering line design (balancing)? b. Line management? c. For making marketing/sales decisions?

a. line balance efficiency (total work content/target manpower x takt time) b. line balance ratio (total work content/no. of stations x longest operation) c. can have accurate target time estimates for production runs when customer quotes are needed

Definition: A visual control is...

an easily identifiable signal that highlights a condition and links to a set of actions

Is visual management used for employees or customers?

both - need to quickly understand visual control sign sign should: 1. shows standard 2. link to action 3. show current condition

What are the 5S's?

sort, straighten, scrub, standardize, sustain

Example of good visual management? why?

stoplight why? •Prevents wastes of waiting (looking for a gap in traffic) •Prevents waste of defects (accidents) •Prevents waste of transportation (avoiding busy intersections)

What are the 3 main components of visual management?

•Shows current condition •Shows standard •Links to action (what gets measured, gets done)