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TOM 3010 - CH 8|85 Quiz Questions
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For jidoka, autonomation to work? - โ โ 1. equipment has to be capable of detecting problem exists
- stopping production
- alerting the operator
How can we determine if a process is lean? - โ โ the operation strives for a reduction of waste in its capacity AND the time a flow unit spends in the system
How does a make to order pull system work? - โ โ Typically each flow unit in a make to order system is already assigned to one specific customer order with a first in, first out (FIFO) basis.
This is different from kanban where a resource may receive the work authorization to make a part but don't determine which customer order it will fulfill
How does a process layout look like for a single unit flow? - โ โ 1. organize work stations matching flow of materials physically together to reduce transportation needs (ex. parts moving from machine 1 to machine 2, these two machines should be close to each other)
- Baton passing zones (Instead of having fixed allocations of activities to workers, the idea of a baton passing zone is that the process can absorb variations in speed and starting time.)
- U-shaped lines (organizing flow in a physical U shape is better than a straight line as it allows workers to help each other from opposite ends)
How does less flow time affect inventory? - โ โ It causes LESS inventory
How is inventory affected by kanban PULL system? - โ โ can never have more inventory between two resources (steps) in a process than authorized by kanban cards
How is inventory affected by push system? - โ โ upstream resource continues to produce as long as it has inputs available --> excess inventory after the step (NO LIMIT TO INVENTORY)
How many kanban containers should management put into system? (number of kanban = how much inventory is allowed to be generated from operations) - โ โ CONTAINER SIZE (larger a container the less kanban needed)
DEMAND RATE (higher demand requires more inventory)
REPLENISHMENT TIME (time to make units per container and transport them to receiver)
SAFETY STOCK (how much inventory extra is needed in case of breakdowns, defects, or other variations)
How to calculate takt time? - โ โ =Available Production Time divided by Customer Demand.
How to find target manpower once we have the takt time? - โ โ =sum of the processing times across all workers / Takt Time
If you have a processing time of 50 secs per unit and a takt time of 10 secs per unit how many workers do you need to meet demand? - โ โ 5 workers
because you only have 10 secs to make a unit according to customer demand but your resource takes 50 secs to complete the unit. Thus, to speed up the process of making one unit to 10 secs, you need 5 people
In a blank system, inventory is a managerial decision. - โ โ pull
In which type of system does production occurs only because there is demand? - โ โ Pull
Is the kanban system a single flow system? - โ โ NO, units are still batched together
LOOK AT TPS MAP IN CH 8 - โ โ LOOK AT TPS MAP IN CH 8
Most organizations use which form of pull systems? - โ โ BOTH
Number of kanban cards FORMULA? - โ โ = (Demand during replenishment time + safety stock) / Container size
Demand during replacement time = replenishment time x demand rate
More transparencies (inventory masks defects/imbalances but WITH LITTLE OR NO inventory between stations the imbalances in speed across resources are easily detected)
What are several ways a one-unit flow exposes/reduces waste? - โ โ 1. LESS INVENTORY (producing to demand allows to reduce inventory)
- SHORTER RESPONSE TIMES TO DEMAND (shorter flow times) - less inventory translates to less flow times
- FASTER FEEDBACK (work in progress inventory holding units don't notify of defect but the next worker in the downstream will be able to catch the defect quicker)
- Simpler and more flexible staffing
- Shorter processing times
- More transparency (inventory covers up defects and imbalances)
What are the 3ms caused by uneven flow process? - โ โ mura (uneven workflow) --> muri (overburdening) --> muda (waste)
What are the four principles driving the TPS at Toyota and operational excellence? - โ โ PHILOSOPHY: long term approach favoring quality over short term financial goals
PROCESSES: process flows that match supply with demand
PEOPLE AND PARTNERS: emphasizing skill development and respectful interactions w employees and partners
PROBLEM SOLVING: ongoing improvement of operations leveraging experience of front-line employees
What are the process changes required to create a single unit flow in a process? - โ โ Implementing a pull system
Transferring units piece by piece requires a change to facility layout
Operating on takt time
Leveling demand rate so takt time does not constantly change and provide flexibility in process to produce different variants of a product
What are the seven sources of production waste? - โ โ 1. WAITING (time on hand) - worker waiting for machine to complete its work basically idle time
- OVERPRODUCTION - producing too much too soon wastes capacity
- INVENTORY - accumulation of inventory that there is a supply-demand mismatch with waste in form of material handling, storage, transportation of inventory
- TRANSPORT - long distances flow units must physically travel through a process is wasteful
- OVERPROCESSING / INCORRECT PROCESSING - redundant or slow work by worker
- REWORK - when product has bad quality and has to be redone again
- UNNECESSARY MOTIONS/MOVEMENTS: there are many ways to do a task but there is only one way that is most optimized and efficient
What are the two approaches to making waste of flow time visible? - โ โ TAKING PERSPECTIVE OF FLOW UNIT - create a simple time line and document what flow unit is doing at each moment of time in journey through process
- processed in HIGH VOLUME / LIMITED VARIETY
- are required with a SHORT LEAD TIME
- costs and efforts to store ARE LOW
What conditions are ideal for using made-to-order pull system? - โ โ products that are:
- processed in LOW VOLUME and HIGH VARIETY
- customers willing to wait for order
- EXPENSIVE or DIFFICULT to store flow units
What does a single unit flow PROCESS LAYOUT look like? - โ โ Work stations ORGANIZED to match flow of materials (if machine a to machine b has lots of part they should be proximally close to each other)
BATON PASSING ZONES
What does Genchi Gembutsu mean? - โ โ go and see in the real place (observation aspect of lean observations where those doing the work would be the ones observing and improving)
What does heijunka focus on to smooth production? - โ โ reducing duration of setup times to allow operation to switch between models frequently
mixes models and avoids large production batches (matches supply with demand)
have a LEVELED production plan that production a set amount per day queud up which will be distributed as needed
What does kaizen mean? - โ โ (continuous improvement)
process improvement
should be done by those familiar with process on the front line and not by an outsider who validates ideas without full picture
What does mura mean in production? - โ โ Unevenness in flow. Due to different models may or may not require a resource so that resource has idle time.
What is a kanban-based pull (order-up-to policy)? - โ โ upstream resource REPLENISHES what demand has withdrawn from the downstream resource
What is a kanban? - โ โ WORK AUTHORIZATION FORMS ('cards') attached to containers that move between upstream and downstream sources connecting and verifying that arrival of an empty container from the downstream source to the upstream will trigger a production order
What is a key element of good / lean operations? - โ โ observation
What is a more narrow scope of studying waste instead of studying waste which focused on the resources? - โ โ waste focused on a flow unit passing through a process
What is a multitask job assignment? - โ โ A technique to reduce idle time by avoiding a worker watching a machine do work. (in a u, a worker does not have to wait after starting machine but walk to another part of the u to complete a task there while the machine is running)
What is a process layout? - โ โ The spatial location of resources in a process that drives the needs for transportation.
What is a push system which we don't want? - โ โ A production system in which flow units are allowed to enter the process independent of the current amount of inventory in the process.
What is a single-unit flow that matches demand (key flow concept in TPS)? - โ โ operate at a flow of ONE UNIT AT A TIME from one resource to the next instead of operating based on transfer batches (group of units).
What is an example of waste of time at a resource? - โ โ IDLE TIME causes waste of capacity
TIME SPENT ON NON-VALUE ADDED WORK also wastes capacity
What is an example of waste of time of a flow unit? - โ โ Reducing flow time reduces the waste associated with a longer flow time it takes to make one unit
= Value added time / total available time
What is process layout? - โ โ similar equipment and functions are grouped together
What is production leveling? HEIJUNKA - โ โ Leveling production by reducing variation in the work schedule that arises from either demand variation or the desire to run production or transports in large batches. This is a principle of the Toyota Production System that strives to have production match the true rate of demand.
attempts to LOWER peaks of production and raise valleys in production as much as possible to achieve a flow with smooth surface
What is scientific management? - โ โ A management framework created by Frederick Winslow Taylor that emphasizes efficiency and optimization.
What is takt time? - โ โ how much time you have to manufacture each piece.
(flow should be happening at rate of demand not by flow of resources)
when demand goes up, takt time goes down
What is taylorism? - โ โ analyzing every movement and work of workers to squeeze out every list bit of productivity from the workforce.
became symbol for how NOT to manage a lean operation
What is the 3 step process to solving problems? - โ โ 1. Jidoka (autonomation with a human touch) (detect problems, stop process, alert operator)
- Kaizen (analyze root cause on the shop floor)
- Poka Yoke (avoid recurrence of problem by implementing improvements) (Fool proofing an operation to avoid the recurrence of defects.)
What is the focus of lean operations? - โ โ reducing waste in the form of wasted flow time or wasted capacity
roots in the auto industry
What is the fraction of flow time that a flow unit spends unproductively/wasted? - โ โ time a unit sits in inventory, transportation times, or setup times
What is the Japanese word for single unit flow? - โ โ ikko nagashi
What is the main advantage of a kanban system? - โ โ there can never be more inventory between two resources than what has been authorized by kanban cards
What is the process layout of organization by function (equipment)? - โ โ ex. a stitching station at bag making company will perform all stitching on the different types of bags created from their respective different stations, it does not make sense to use single unit flow layout where each bag station needs its own separate stitching station to complete the stiching process.
What is the Toyota Production System (TPS)? - โ โ A framework used to run operations with the goal of reducing both the waste of capacity and the waste of flow time, thereby making sure supply and demand are matched just in time. (optimal transfer batch is equal to one)
What is the value-added percentage? - โ โ The percentage of flow time used for value-added work.
= value-added time of a flow unit / flow time
What is total available time of a process resource? - โ โ The amount of time a resource has available to fulfill demand.
consists of waste, value added work, and nonvalue added work
What is TPS house? - โ โ A representation of the Toyota Production System in the shape of a house with the roof capturing the main goal of the TPS, which is waste reduction; the pillars being just-in-time flow and built-in-quality; and the foundation being process improvement.
What popular jidoka tool is used? - โ โ ANDON - A system consisting of a visible board and a cord running adjacent to the assembly line. An employee who detects a problem can pull the cord to stop the line. This will be indicated on the board.
What two key concepts characterize TPS approach to root cause problem solving? - โ โ Kaizen (continous improvement, The process of making small changes to the process with the goal of eliminating waste.)
TAIICHI OHNO
Why is Taylor's scientific management (Taylorism) not a good example for modern lean operation? - โ โ Taylor saw workers as muscle not brains and just wanted them to blindly follow what operation engineers wanted them to do (mistreatment)
workers would have to work more as standard output increases due to shorter processing times
workers that were rewarded for high output does not care about quality and defects
Why is the added value of a flow unit not exactly the same as its labor content? - โ โ All processing times do not add value.
