TOM 3010 Mid-Term Review
Genchi Genbustu
(Go and See) - Gather firsthand information from the situation by going and observing the situation yourself, collection date, and analyzing the data
The architecture of the Toyota Production System
- Make to Order - Pull System
Standard Work Considerations
- Safety and ergonomics - Quality - Cycle Time - Takt Time - Process Knowledge
Kai Zen
- To take apart - Think about - Put back together in a better way
Flow can be _______________ process capacity.
-Equal to - Less than
5S
1. Sort 2. Set in Order 3. Shine 4. Standardise 5. Sustain
Throughput
A synonym for flow rate
Andon
A system consisting of a visible board and a cord running adjacent to the assmebly line. Any employee detecting a problem can pull the cord to stop the line.
Multitask Job Assignment
A technique to reduce idle time by avoiding a worker watching a machine to work.
Demand levling
A way to sequence flow units so that the workflow causes a stable workload for all workers involved in the process
Machine Pace
All steps are connected through a conveyor belt and all of the steps must work at the same rate even if some of them have more capacity to pass through the entire process
Labor Content
Amount of work that goes into serving one customer as the input into the process and turning that customer into a served customer
Muri
An unreasonable amount of work, overburdening a machine or operation
Autonomation
Automation with a human touch; use machines but combine them with the intelligence of the workers
To increase the capacity of a process one must increase the capacity of the resource that is the ___________.
Bottleneck
Flow units waiting in the process without being worked on are often referred to as __________ inventory.
Buffer
Inflexibility is the inability of an operation to quickly and ____________ change in response to new information
Cheaply
The _______________ rate is the number of flow units that customer want per unit of time.
Demand
Process Capacity
Determines how many flow units can be processed per unit of time (Units/TIme)
Where there are 10 call center operators scheduled but only 9 show up there is variability due to _____________
Disruptions
Worker Pace
Each worker is free to work at his or her own pace
"Lead time" is sometimes defined as the time between initiation and completion of a production process. Which process metric is a synonym for lead time?
Flow Time
Little's law states that inventory = Flow Rate * _______________
Flow Time
Poka-Yoke
Fool proofing an operation to avoid the recurrence of defects
Resources help the flow units to move from being a unit of ____________ to a unit of ____________.
Input to Output
Which metric is most difficult to calculate directly?
Inventory
______________ is sometimes a mismatch between supply and demand.
Inventory
The longer the average flow time, the ____________ the average inventory level.
Larger
The less you have to wait the _________ the inconvenience component.
Less
Heijunka
Levling production by reducing variation
U-Shaped Line
Locating resources in a U-shaped layout, which increase the flexibility of works to perform multiple taks
Make to Order
Making the activation of resources in a process contingent on receiving a specific order.
Customers willing to pay for same day shipping are in a different ________ segment from those willing to save money by waiting two days for their order to arrive.
Market
Customers buy products that _________ their utility.
Maximize
The further the location the ___________ the inconvenience component.
More
Inventory
Number of units within a process
Single-unit flow
Operate at a flow of one unit at a time from one resource to the next instead of operating base don transfer batches.
Value-added work
Operations valued by customers because they are required to transform the flow unit from its inputs to becoming what the customer wants
Continuous Flow
Producing ad moving one time at a time through a series processing steps as continuously as possible, with each step making just what is requested by the next step.
If the first customer to a restaurant wants a salad and the second wants a sandwhich then there is variability in customer ______________.
Requests
___________ are the things a business uses to help transform inputs into outputs.
Resources
The goal of operations management is to match ___________ with __________
Supply with demand
Just-in-time Production (JIT)
Supplying a unit of demand when and where it is needed, avoiding unnecssary inventory
Flow Rate
The Rate at which flow unit's travel through a process (Units/Time)
Average Labor Utilization
The average utilization across resources
Flow Unit
The basic unit that moves through a process
Capacity-Constrained
The case in which demand exceeds supply and the flow rate is equal to process capacity
Demand-Constrained
The case in which process capacity exceeds demand and thus the flow rate is equal to the demand rate
Standard Work
The current best way we know how to do the work today.
Costs of Direct Labor
The labor cost associated with serving one customer
Demand Rate
The number of flow units that customers wants per unit of time
Upstream
The parts of the process that are at the beginning of the process flow
Downstream
The parts of the process that are the end of the process flow
Detect-Stop-Alert
The philosophy of halting production when a quality problem is discovered
Takt Time
The ratio between the time avaialable and the quantity that has to be produced to serve demand
Pull System
The resource furthest downstream (closest to market) is paced by market demand. In addition, it also relays the demand information to the next station upstream, thus ensuring that the upstream resource also is paced by demand.
Flow Time
The time a f low unit spends in a process, from start to finish
Information Turnaround Time
The time between creating a defect and receiving the deedback about the defect
Processing Time
The time it takes resource to complete one unit flow (Time / Flow unit)
Idle Time
The time we pay resources when they are not working
Non-Value Added work
Those operations 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 the unit
Lead Time
Time between a customer placing his or her order and that order being filled. Lead time is thus we previously defined as Flow Time.
Cycle Time
Time between two consecutive units (time/unit)
Time through empty System
Time for the first customer to pass through the entire process
Price includes the ______________ cost of owning the product of receiving the service.
Total
You should choose a flow unit based upon what you want to ___________ and __________.
Track and Measure
What shape is used to represent flow units waiting in a system (buffer inventory)?
Triangle
Mura
Unevenness in flow
Jidoka
Upon detection of a problem, shutting down the machine
___________ is the inhibitor that corresponds to changes in either demand or supply.
Variability
The three sources of inefficiency are ____________, _________________, and __________________. (Three system inhibitors)
Waste, variability, and inflexibility
Process ________ determines the maximum flow rate a process can provide per unit of time.
capacity
Process __________ determines thew maximum flow rate a process can provide per unit of time.
capacity
When the flow rate is less than the demand rate the process is referred to as ___________ constrained.
capacity
When organizations make a trade-off they focus on meeting one dimension of ______________ utility in favor of another.
customer
If the cycle time for a process goes down then the time to finish X units starting with empty inventory buffers will ____________
decrease
If processing time increases, then the capacity at a resource with a single employee ____________.
decreases
Waste __________ add value to the customer.
does not
Inventory is the number of __________ units within the process
flow
The larger the average flow rate, the _________ the average inventory level.
larger
For a given level of revenue, the higher the costs the ________ the profit.
lower