TOM 301 Ch. 8 Homework

Conceptual Question 8-23 A single inspection... 8. A single inspection system with experts testing the output of the process will help reduce the information turnaround time. - True - False

- False

PA 8-7 The welding department supplies parts to... 3. The welding department supplies parts to the final assembly line. Management decides to implement a kanban system and has collected the following data. - The daily demand is 2,300 units - The production lead time is 6 days (this includes processing time, transport time, and waiting time) - Management has decided to have a 2 day(s) safety stock - One container fits 425 units. How many kanban containers will be needed to support this system?

Number of kanban cards = [(Replenishment time*Demand rate) + Safety stock] / [Container size] = [(6x2300)+(2x2300)] / [425] = 18400/425 = 43.2941 = *44 kanban containers needed*

Conceptual Question 8-19 Because of long set-up... Because of long set-up times, a company chooses to run big production batches. Which of the following actions will level the production schedule? - Using overtime - Mixing the models on the final line - Making sure that rework is kept low - Reducing the waste of the process

- Mixing the models on the final line

Conceptual Question 8-18 What happens to the... 4. What happens to the number of Kanban cards in the process if the replenishment time goes up? - The number of Kanban cards increases - The number of Kanban cards stays the same - The number of Kanban cards decreases - Cannot determine from the given information

- The number of Kanban cards increases

Conceptual Question 8-25 Which of the following... Which of the following terms is not part of the Toyota Production System (TPS)? - Ikko-nagashi - Kanban - Jidoka - Yakimono - Genchi genbutsu

- Yakimono

A 8-4 In the welding operations of a bicycle manufacturer... 2. In the welding operations of a bicycle manufacturer, a bike frame has a flow time of about 14.5 hours. The time in the welding operations spent as follows: 1 hour waiting in front of the cutting machine for the batch to start, 2 hours waiting for the setup of the machine, 2 hours waiting that the other pieces of the batch go through cutting, 1 minute at the cutting machine, and 3 hours waiting for the transfer to the welding machine. Then, at the welding machine, the unit spends 2 hours waiting that the other pieces of the batch go through cutting, 0.75 minutes at the welding machine, and 2 hours waiting for the transfer to the next department. Determine the exact flow time. What is the value-added percentage of the flow time?

Flow time = (1 hr + 2 hr + 2 hr + 3 hr + 2 hr + 2 hr + 0.5 hr + 2 hr)*60 + 1.75 min = 871.75 min Value-added time = 1 min + 0.75 min = 1.75 min Value percentage of flow time = 1.75/(871.75) = 0.002007 = *0.2007%*

PA 8-3 A copy machine is available ... 1. A copy machine is available 24 hours a day. On a typical day, the machine produces 89 jobs. Each job takes about 5 minutes on the machine, 3 minutes of which is processing time and 2 minute is setup time (logging in, defining the job). About 15% of the jobs need to be reworked, in which case the set-up time and the processing time have to be repeated. The other time, the equipment is idle. What is the OEE of the equipment?

Overall Equipment Effectiveness OEE = Value add time/Total time avaliable = (89x3)/(24x60) = .1854 = *18.5%*

Conceptual Question 8-13 If the demand rate... 6. If the demand rate increases, the takt time: - Increases - Decreases

Takt time = Available time/Demand rate - Decreases

Conceptual Question 8-14 If the takt time... 5. If the takt time increases, the operation requires: - More workers - Fewer workers

Takt time = Available time/Demand rate Target manpower = Labor content/Takt time -Fewer workers

Conceptual Question 8-4 Students have to change... 7. Students have to change buildings between classes, which often times invovles walks of 5 minutes or more. Walking from one building to another is: - Waste - Non-value add time - Value add time - Cannot determine from the given information

Waste = The needless waste of time and worker movements that ought to be eliminated immediately. This includes, for example, idle time or fixing broken units. Non-value added time = Those operations that do not add value in the eyes of the customer but must be done under the current conditions of the process in order to complete a unit. - Non-value added time