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
