IT 403 Final
What are some of the benefits of flow?
-Ability to cross train is enhanced -Reduced Cycle Time -Drives Set-Up Times Down -Reduces Material Handling -Quick Problem Identification
What is the process for implementing a pull system?
1. Map the Current State 2. Address Barriers to Pull 3. Determine Customer Scheduling Strategy 4. Design a Communication System 5. Train People to use the pull system 6. Define Inventory Locations 7. Start at Customer and Implement Upstream
What are the steps to a VSM?
1. Select one value stream - product family 2. Walk the physical flow of material 3. Walk the flow again collecting data 4. Draw the Current State Map 5. Identify opportunities to eliminate waste and create flow 6. Draw the Future State Map 7. Generate a Value Stream Plan 8. Start making the improvements 9. Conduct Value Stream Reviews 10. Repeat The Cycle
Company uses a Kanban system to manufacture bulk mustard in gallon containers for restaurants. The demand for container lids over an eight-hour production day is 1000 units. The average waiting time for a container of lids is 45 minutes. The processing time for a container of lids is 2 hours, and a container holds 70 lids. How many Kanban containers would Mike's Mustard require if a 5% policy variable is used?
5 or 6
Jones Electric Motors uses a Kanban system to make motors for several garage door companies in the southeastern United States. The daily demand for motor housings used in manufacturing is 100 units. The average waiting time for a container of parts is 0.2 day. The processing time for a container of housings is 0.1 day, and a container holds 5 housings. If Jones wishes to use a 10% policy variable, how many containers are needed?
7 containers = [100*(.2+.1)(1+.10)] / 5
What percentage of total steps are waste from the standpoint of end customer?
80 to 90%
What is a Heijunka Box?
A load leveling box with a columnn for Kanban slots for each Pitch interval and a row of Kanban slots for each product type. This tool indicates both the quantity produced and the time allocated to make it.
What is the manufacturing paradigm?
A manufacturing model that has a set of principles by which it can be explained. Cost, Quality, Variety
Define Kanban.
A signal that provides an instruction to regulate the sequence and timing of production.
What exactly is VSM?
A visual representation of all the steps needed for: Concept to Launch (Design) Order to Delivery (Build) Delivery to Recycle (Sustain)
Which of the following is a process consideration in the implementation of a lean system? A) Firms might have to change existing layouts. B) Workstations typically will have to be moved farther apart. C) A contract with strict job classifications will have to be adopted. D) Plant access by rail will become necessary.
A) Firms might have to change existing layouts.
When implementing a lean system: A) managers can mitigate some of the effects of worker stress by judiciously using safety stocks and emphasizing material flows rather than worker pace. B) management should base the reward system on production volume. C) the plant layout is the only environmental characteristic that need not be analyzed. D) it is critical to develop a master production schedule that changes frequently as forecasts change.
A) Managers can mitigate some of the effects of worker stress by judiciously using safety stocks and emphasizing material flows rather than worker pace.
Which of the following statements about the Toyota Production System is best? A) Toyota has built a learning organization over the course of 50 years. B) The key to success for Toyota is the set of tools and procedures readily apparent on a plant tour. C) The four principles that form the basis to TPS are impossible to replicate. D) Toyota has 23 manufacturing plants in North America alone.
A) Toyota has built a learning organization over the course of 50 years.
Define Kanban.
Any signal used to directly communicate production or delivery information between those people performing the work.
Lean systems try to : A) Produce a product in anticipation of demand. B) Maximize the Value added by of each of its activities. C) Organize production in large lots to minimize the number of setups. D) Reduce the Labor Content in all Processes
B) Maximize the value added by of each of its activities
Companies using lean systems generally have: A) Many suppliers to ensure that material shortages never occur. B) Suppliers that are located nearby to decrease delivery lead time C) Suppliers that are willing to accept short-term contracts D) Suppliers who are low cost producers
B) Suppliers that are located nearby to decrease delivery lead time
What's the difference between Batch & Push and Continuous Flow?
Batch and Push make a certain amount and then passes it on while continuous flow is make one, move one.
Continuous improvements with lean systems: A) Involves navigating a ship over treacherous rocks B) Requires periodically increasing lot sizes or workforce levels to uncover problems. C) Entails systematically stressing the system and focusing on problem areas D) Focuses exclusively on internal operations without addressing relationships with customers and suppliers
C) Entails systematically stressing the system and focusing on problem areas
Which one of the following is an advantage of lean systems? A) Lean systems reduce equipment needs by using larger lot sizes. B) Lean systems can be implemented in any production environment. C) Lean systems result in a decrease in safety stock and work-in-process inventory. D) Lean systems result in an increase in manufacturing lead times.
C) Lean systems result in a decrease in safety stock and work-in-process inventory.
Implementing a lean system: A) has the advantage that workers have less stress because of the routine, repetitive work they perform. B) typically relieves the workers and first-line supervisors from activities such as scheduling, expediting, and productivity improvements. C) requires an examination of the reward system to make sure it is consistent with the JIT philosophy. D) involves the reorganization of material flows to that of a flexible flow.
C) requires an examination of the reward system to make sure it is consistent with the JIT philosophy.
To pursue perfection... Every step in each process is _____, _______, ______.
Capable (Six Sigma) Available (TPM) Adequate (Capacity to Avoid Bottlenecks)
What is the foundation of Toyota?
Customer First Respect for Humanity (social, economical, ecological) Continuous Improvement (Kaizen, "Everyone, Every Day, Everywhere") Gemba First (Gemba = Place of Work)
A value stream can be one of what four things?
Customer or Customer Category Product or Product Family Plant Service
An important mechanism for lean systems is a Kansan system. Which one of the following statements correctly describes the behavior of a two-card Kanban system? A) A withdrawal Kanban is issued to authorize production in the fabrication process. B) A production-ordering Kanban authorizes the assembly process to remove the materials from the storage location. C) The fabrication process produces certain units defined by the lot size and pushes them down to the assembly process. D) Containers must never be removed from the storage location without an authorizing withdrawal.
D) Containers must never be removed from the storage location without an authorizing withdrawal Kanban.
Which of the following actions would increase the number of containers in use in a Kanban system? A) using larger containers that can hold more parts than before B) less demand for the part held by the container C) faster processing times for the part held by the container D) increased waiting time for the container
D) Increased waiting time for the container
The just-in-time (JIT) system is a(n): A) Management system of people and procedures to fulfill all delivery deadlines B)Production system of small-lot manufacturing to reduce work in process inventory C) Materials management system for removing all inventories D) Integrated system of managing resources, information, and decision processes to eliminate waste.
D) Integrated system of managing resources, information, and decision processes to eliminate waste
Which of the following actions would decrease the number of containers in use in a Kanban system? A) smaller containers that can hold fewer parts than before B) higher demand for the part held by the container C) increased waiting time for the container D) faster processing times for the part held by the container
D) faster processing times for the part held by the container
Define these terms. Demand Available Work Time WIP Finished Goods
Demand -# of units/day the customer wants Available Work Time -Scheduled Work time-breaks, meetings, and clean up time WIP - #of units waiting to be worked on Finished Goods - #of units in stores or waiting to be shipped
What are the two set of tools of visual management?
Displays --Make Staff Aware with Charts, Graphs, Etc Controls --Guide actions of Staff with dos and don'ts signs
What are some of the things that created the Lean Manufacturing today?
Eli Whitney -Interchangeable Parts Henry Ford -Assembly Lines Toyota - Daichi Ono -Production
What goes into Check?
Evaluate Results
What goes into Do?
Execute an Idea
What are the seven main sources of waste?
Extra Inventory Time Movement Transportation Skills Defects Over Production Over Processing **Skills (8th)
True or False. While overproduction creates an item before it is needed, the extra time before an item is needed makes it easier to detect defects and reduce their impact on a process.
False
True or False. Focus on the upstream processes.
False Downstream
True or False. In a lean system, large inventories are not considered a type of waste, because they prevent operator wait times.
False.
True or False. In a VSM, Information flow is drawn from left to right in a map.
False. It's right to left.
True or False. Any process before the pacemaker process must be continuous flow.
False. It's after.
A _________ is a group of items that pass through similar processing steps and over common equipment
Family
Define Continuous Flow Production.
Flow of products in a level manner through the production operations. The intent is to increase the velocity of products and make the production cycle predictable.
What goes into Plan?
Identify the Condition Analyze the Current State Develop Ideas Develop Hypothesis
What goes into Act?
If experiment did not produce desired result, determine why? and revise. If experiment produced desired result, expand, solution, adopt, continue to look for improvements.
What process improvements will be necessary for the value stream to flow as your Future State Map specifies?
Improvements to -Equipment -Procedures -Changeover Time -Yield -Cycle Time
What are the types of floor layouts? What's the best?
Island --Traditional, Scattered Linear --Straight Line Multi-Machine --Group like "U" Shape --Best arrangement Connected Lines
A process that is automatically stopped when something is wrong and then fixed on the line is called what?
Jidoka
________ is the philosophy that waste can be eliminated by cutting unnecessary inventory and removing non-value-adding activities in operations.
Just in Time
A ________ Kanban is a card used to control the flow of production through a factory.
Kanban
Where can't we use continuous flow?
Long Set-Ups Large Distances Downtime Problems Long Lead-Times
For continuous flow product remember these three things...
Make It Flow Feed the Flow Link the Flow
What are the three components to waste reduction?
Material People Processes
What's part of the interview process that stands out for Toyota?
Ohno Circle -Stand in this circle in the production line and find improvement
What are some wastes?
Overproduction Waiting Transportation Inventory Unnecessary Processing Unnecessary Motion Correction
At what single point will you schedule production?
Pacemaker Process -How you control the production here sets the pace for all of the upstream processes.
What does PDCA stand for?
Plan - Do - Check - Act
What are the types of visual display?
Product and Process Information Area Info, Boundaries Standard Work Instructions Performance Information Status of Current Issues Schedules of Maintenance
__________ Kanban contains all information needed to communicate a production order or a delivery order.
Production i.e. Cards Empty Bins Call Light Electronic Floor Location
What are the two types of Kanban?
Production Withdrawal
What method is better for highly repetitive processes?
Pull
___________ system allows production of smaller lots of products, reducing lead time.
Pull
Define Pull
Pull Means that no one upstream should produce a good or service until the customer downstream asks for it. -Only replacing a product that a customer wants or takes
What are some of the benefits of an integrated system?
Reduces cost Improves Quality Saves Time
What are the goals of a competitive company?
Satisfy the Customer
Production Kanban
Signal (Triangle) - Processes with long setup times Call - Where use of a physical card is not practical Regular - All other prod. kanbans
A _______ Kanban is sent to the stamping process whenever the number of bins remaining drops to a trigger (minimum) level.
Signal or Batch
What are the techniques of Flow?
Step 1: Focus on Actual Object Step 2: Ignore Traditional Boundaries of : Jobs, firms, functions Step 3: Rethink Specific Work Practices and Tools *All three MUST be taken together
Withdrawal Kanban
Stock - Material pulled from in-house storage location Supplier - Material ordered from external supplier
What are the three main ways A3's can be used in an activity?
Strategic Planning Problem Solving/Decision Making Value Stream Analysis
______ used when continuous flow is interrupted
Supermarket
________ is a graphic representation of the Toyota Production System showing all of the essential elements of lean systems that make the TPS work well.
The House of Toyota
Briefly discuss the House of Toyota, including its origins and key points
The House of Toyota is a graphic presentation of all the essential elements of lean systems that make the Toyota Production System (TPS) work well. It was originally used by Toyota to define TPS to its employees and suppliers. Its roof represents the primary goals of high quality, low cost, waste elimination, and short lead times. The roof is supported by the twin pillars of JIT and jidoka, which stand on a base of operational stability that comes from leveraging a number of lean concepts.
What is Take Time? What is it also described as?
The principal that all activity within a business is synchronized by a pulse, set by customer demand. Metronome total time available / total customer demand
Define Mass Production. Name the example of this production stated in class.
The process of producing a limited variety of standardized products at low cost as a strategy that increases customer demand and allows market expansion. Eg. Ford Model T "You can have any color of a car you want, As long as it's black"
Cycle Time
The time between one part coming off the process and the next part coming off
What is the Process Lead Time?
The time for a unit to make it all the way through the process. Sum of Inventory Days + Sum of Cycle Times
Define Production Lead Time
The time it takes for a part to make its way through the shop floor beginning with the raw material
What is the process time?
The time spend actually performing work on the unit Sum of Cycle Times
The ____________ summarizes the current condition of the value stream.
Timeline
What are the three parts that make up Human Development?
Tools Management Guiding Principles
Describe the Iceberg Model
Top - Results (Reactive) Middle - Pattern (Proactive) Bottom - Systems (Generative)
_______ practices include early testing of machine parts that may need to be replaced and making workers responsible for routine minor maintenance of their own equipment.
Total Preventive Maintenance
8 Types of Waste
Transportation Inventory Movement Waiting Overproduction Over-processing Defects Skills Not Used (8th)
True or False. Heijunka is the leveling of production load by both volume and product mix.
True
True or False. Lean systems are operating systems that maximize the value added of each of its activities by paring unnecessary resources and delays from them.
True
True or False. Take time is the cycle time needed to match the rate of production to the rate of sales.
True
True or False. A kanban is a card used to control the flow of production in many just-in-time systems.
True
True or False. In a lean system, wait times can be caused to some extent by long production runs.
True
True or False. Just-in-time systems need close relationships with suppliers.
True
True or False. Kaizen is the Japanese term for continuous improvement.
True
True or False. Long production runs, poor material flows, and processes that are not tightly linked to one another can cause over 90% of a product's lead time to be spent waiting.
True
True or False. The just-in-time philosophy is the belief that cutting inventory and removing non-value added activities in operations can eliminate waste.
True
True or False. VSM has two flows: Orders traveling upstream from customer, Products traveling downstream to customer
True
True or False. When walking the flow, begin at shopping.
True
True or False. Inventory is measured in days.
True # of units/ demand per day
_____ ____ used to regulate production.
Two Bin
All steps in a VSM is...
Value Added Non-Value Added
What is the difference between the "push" and "pull" methods of material flow? Which method does lean systems use?
With the pull method, customer demand (an order) activates the production of the goods or services. The production system does not anticipate the need for more product until indicated by a customer order. The push method begins with a production schedule and customer demand is assumed (or hoped for). Lean system processes use the pull method of production.
Happiness, Inc. uses a Kanban system. The daily demand for the most critical part, the Smylie, is 400 units over an eight-hour production period. The average waiting time for a container of Smylies is 30 minutes. The processing time for a container filled with Smylies is 6 minutes, and a container holds 5 units. If the company wishes to use a 5% policy variable, how many containers are needed?
[400*(.0625+.0125)(1+.05)]/5 7 containers
Champion Cooling Company uses a kanban system at their two locations in the Oklahoma City Metroplex. The daily demand for fans is 2000 at each location and management insists on using the same alpha level (0.1) at both locations. Location Reno uses containers that hold 20 items and takes 0.04 of a day to process a container. It takes 0.07 of a day to get a container filled and for it to wait during its cycle. Location Western uses containers that hold 24 items and takes 0.02 of a day to process a container. It takes 0.08 of a day to get a container filled and for it to wait during its cycle. Which location has the higher level of inventory? Assume that both locations round up to the next highest integer number of containers.
k_reno = [2000*(.04+.07)(1+.1)] / 20 = 13 WIP_reno = 20* 13 = 260 k_western = [2000(.02+.08)(1+.10)] / 24 = 10 WIP_western = 24*10 = 240
