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OTM 300 Exam 1 With Complete Solutions 100% Verified
What is the term for stopping a machine when an abnormal condition is detected? -ANSWER Jidoka
A one unit flow often requires a facility layout to minimize the need for _______ batching -ANSWER transport
Non-value added work - ANSWER necessary because of how current process operates Value-added work - ANSWER Necessary to transform flow unit from inputs to output thecustomer wants
The more available time, the _______ the takt time - ANSWER Higher Information turnaround time - ANSWER The time between creating a defect at anupstream resource and detecting it at a downstream resource
Kanban System - ANSWER Production instructions are communicated to an upstreamstep when there is consumption at a downstream step
Likely improvement method for a Demand Constrained process - ANSWER Reducecosts
Likely improvement method for a Supply Constrained process - ANSWER Increase flowrate
Taylor's Theory - ANSWER Workers are animals who need to be trained to perform workin the manner designed by engineers
Autonomation - ANSWER automation with a human touch To implement a single unit flow, you should level: - ANSWER the demand rate To implement a single unit flow, you should operate at: - ANSWER takt time To implement single unit flow, you should implement which type of system? - ANSWERPull
Utilization is always ______ implied utilization - ANSWER equal to or less than With multiple flow unit types, the bottleneck is the resource with the _________ impliedutilization - ANSWER Highest
The process is capacity constrained you compute the flow rate for a particular type offlow unit you divide the demand rate by : - ANSWER the highest implied utilization For the flow rates across units you: - ANSWER add the flows in each unit To compute total demand rate for a resource - ANSWER you sum down the appropriaterow in the demand matrix entries
Implied utilization tells us. - ANSWER how much demand exceeds the capacity of theprocess
Idle time - ANSWER worker time that is not used in the production of the finishedproduct
the "just right" batch size makes a trade-off between: - ANSWER capacity and inventory
the looser the design specifications (larger quantity USL-LSL), the ____ the targetspecifications - ANSWER larger
four dimensions of performance - ANSWER 1. cost
- quality
- variety4. time
3 inhibitors leading to inefficiencies - ANSWER 1. waste
- variability
- inflexibility Utility definition - ANSWER a measure of customer preference (satisfaction) for aproduct or service
three components of utility - ANSWER 1. consumption utility
- price3. inconvenience
what is consumption utility? - ANSWER a measure of how much a customer likes aproduct or service, ignoring price or inconvenience
what is PRICE as an element of utility? ANSWER the full cost of keeping a product orenjoying a service, this would also include shipping and financing
what is INCONVENIENCE as an element of utility? ANSWER the cost of utility related to,or caused by, an effort to obtain product or service
process (definition) - ANSWER a set of activities that take a collection of inputs, perform
some work or activities with those inputs, and then yield a set of outputs Process flow diagram (definition) - ANSWER A graphical way to describe a process-- boxes depict resources -- arrows depict flows-- triangles depict inventory location
flow unit (definition) - ANSWER a unit that can be used to measure and describe all ofthe activities within the process
process metric (definition) - ANSWER something we can measure that informs us aboutthe performance and capability of a process
3 main process metrics - ANSWER 1. Inventory2. Flow Rate
- Flow time what is a flow rate? - ANSWER the rate at which flow units travel through a process what is flow time? - ANSWER the time a flow unit spends in a process, from start to finish what is the definition of inventory? - ANSWER number of units within a process little's law - ANSWER I = R x T avg. inventory = avg. flow rate x avg. flow time what is a stable process? ANSWER long run average inflow rate is the same as the longrun average outflow rate
what is lead time? - ANSWER time between when an order is replace and when it isreceived by the customer
what is a bottleneck? - ANSWER the resource with the smallest capacity how can little's law be written to include cycle time? - ANSWER since little's law is I = R *T and flow rate is 1 / cycle time, little's law can be written as I * cycle time = flow time
time to make Q units (equation) - ANSWER cycle time * Q or 1/flow rate * Q time through an empty system (definition) - ANSWER the time a flow unit takes to gothrough a process that has no inventory in it; Time through the empty system - ANSWER number of stations * cycle time Time to complete x units-ANSWER Time through the empty process + [(x-1)*cycle time] profit maximization (equation) - ANSWER profit = flow rate * [avg price - avg cost] what is an efficient process? - ANSWER a process which can get a high flow rate for afew resources
costs of direct labor (definition) - ANSWER the cost of the labor which serves onecustomer
Costs of direct labor - ANSWER the total wage paid per unit of time / by the flow rate. Labor Content (definition) - ANSWER time required to serve one customer
Average labor utilization (definition) - ANSWER the average utilization across resources Average labor utilization (equation) - ANSWER (labor content) / (labor content + directidle time) (labor content / # of employees) / cycle time idle time (definition) - ANSWER Wages paid for unproductive time idle time (equation) - ANSWER cycle time - processing time Total idle time (definition) - ANSWER sum of idle time per flow unit across all resources Takt Time (definition) - ANSWER time available / quantity that must be produced to servedemand
takt time (equation) - ANSWER 1 / demand rate oravailable time / required Q
what happens to takt time if demand increases? - ANSWER takt time decreases; moreemployees are needed for the same labor content
Target manpower (definition) - ANSWER determines the minimum number of resourcesrequired to meet demand
target manpower (equation) - ANSWER labor content / takt time 3 ways to off-load the bottleneck - ANSWER reassignautomate
what does process capability depend on? - ANSWER the comparison of the currentamount of outcome variation against outcome specifications
what should be used to measure the capability of a process? - ANSWER variation inoutcome variables
what is a robust process? - ANSWER a process where variation in input orenvironmental variables does not result in a large variation in the outcome variables
the larger the sample size, the _____________ the estimated standard deviation -ANSWER smaller
