Chapter 3 Flashcards
(26 cards)
Explain how design simplification can be applied to the manufacturing process
a simple design can reduce the number of operations that product making takes place in manufacturing
how is operation analysis related to methods engineering
operations analysis is focused to produce the improvement so operation analysis is one technique for methods engineering to accomplish the defined goals
what are the 5S pillars
- sort (seiri)
- set in order (seiton)
- shine (seiso)
- standardize (seiketsu)
- sustain (shitsuke)
compare and contrast operations analysis with the lean manufacturing approach
These overlap with traditional methods engineering:
- delays and transport elements are reduced using flow process charts
- excess motions are eliminated
- overproduction and excess inventory
- defective products are a waste and need to reduced
what is meant by “tight” tolerances
accepted tolerance is +/- 0.002
tight tolerance +/- 0.001
explain why it may be desirable to “tighten up” tolerances and specifications
the importance of tight tolerance ensures the fitment of the parts do not fail and performs as they’re meant to. The manufactured parts and products that meet tight tolerance result in highest quality standards and greater customer satisfaction that the right designs is made
what is meant by lot-by-lot inspection
It is a sampling procedure in which a sample is examined to determine the quality of the production run or lot. The size of the sample depends on the allowable percentage of defective unity and the size of the production lot being checked
what six points should be considered when endeavoring to reduce material cost
- find materials that are less expensive
- find material that are easier to process
- utilize the material more economically
- utilize tools and supplies economically
- use salvage material
- standardize the material
how does a changing labor and equipment situation affect the cost of purchased components
labour intense products are dramatically affected by the hourly rates of labour, for the output per unit of time of production has a major impact on product class
what process is usually considered the fastest for forming and sizing operations
a press operation is usually considered the fastest for forming and sizing
how should the analyst investigate the setup and tools to develop better methods
the analyst should determine the quantity to be produced, the chances for repeat business, the amount of labour involved, delivery requirements and the amount of capital required
give some applications of bar coding for the improvement of productivity
the barcode on the product provides the information of size, packing quantity, department of that product, its storage number and the remaining stock level of that product. This information helps to reduce the inventory timely.
what are the two general types of plant layout and explain them both
Product layout and process layout
Product layout - all machines are arranged in the flow of operations required for manufacturing the product. this is meant for mass production and for less job variety.
Process layout - similar machines are grouped in one section or department. It is like group technology, it is meant for the manufacture of moderate production and for more job variety
what is the best way to test a proposed layout
the best way to test a layout is to trace the flow of the various products or product lines
which questions should the analyst ask when studying work performed at a specific workstation
- are both hands working at the same time and in opposite symmetrical directions?
- is each hand going through as few motions as possible?
- is the workstation arranged so that long reaches are avoided
- are large muscle used for force and small muscles for precision
- is muscle for maintained below 15%
explain the advantages of using a checklist
- provides methods training to factory foreman and superintendents
- constructive ideas
- remind the errors that can be avoided
On what does the extent of tooling depend?
amount of tooling depends upon the quantity to be produced, the probability or chance for repeat business and the labour content of the operation
How can a material best be handled?
- material must be moved periodically from one location to another
- material must be arrived in time for production without any hampering
- material must be delivered to the right place
- material must be delivered at each location of production without any damage and proper quantity
- material must have storage space for temporary and also dormant
Why does the travel chart have greater application in process layout than in product layout?
the travel chart is more in process layout as grouping of the equipment in one department already provides short distances between successive operations in the production of product
Where would you find application for a hydraulic elevating table?
hydraulic lift tables would be used in storerooms, stockrooms, tool cribs, and punch press facilities were dies are frequently changed
What is the difference between a skid and a pallet?
the pallet has a bottom covering and to be moved it must be lifted by a fork lift. a skid does not have a bottom, it is usually of heavier construction, and can be moved with a load by a variety of means
What is the analyst’s cardinal rule
Try to eliminate or combine an operation before trying to improve it
What are travel charts?
Travel charts are useful to identify the problems related to the location of equipment as well as arrangement of departments and service within the plant.
What are travel charts?
Travel charts are useful to identify the problems related to the location of equipment as well as arrangement of departments and service within the plant.
