Lean Quiz - Dr. Black's Notes Flashcards Preview

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Flashcards in Lean Quiz - Dr. Black's Notes Deck (32):
1

What does TPS try to minimize and why?

- people
- inventory
- they don't depreciate in cost

2

TPS - Ohno - what did he do?

- reconstructed Job Shop (Mass Production) into manufacturing cells (Lean Production)
- turned final assembly into mixed model

3

4 horsemen of lean manufacturing

1. Cost
2. quality
3. lead time
4. flexibility

4

Flexibility (one of 4 horsemen of lean manufacturing)

- the capability of a manufacturing system to respond quickly to changes
- volume flex - changes in customer demand
- product flex - changes in product design
- lead time flex - ability to respond to customer orders

5

Lean Production

- a system design composed of linked cells which can identify and eliminate waste (non-value added activities) to produce perfect goods at demand (pulls) of customers
- want to reduce TPT - to do so, identify and eliminate largest time traps using design rules for lean eng.

6

Manufacturing System

- a complex arrangement of physical elements characterized by measurable parameters

7

Flow Shop

- developed/used by Ford
- processes all lined up - sequenced

8

Job shop

processes collected in departments

9

Project Shop - fixed position layout

thing being manufactured there is so big that it cant be moved around the shop --- civil engineers

10

Continuous Process Layout

for oils, gases, etc. ---- Chemical engineers

11

Little's Law

WIP = TPT X PR

12

Takt Time

TT = 1 / PR

13

Manufacturing System:
-how to control system
- rules

1. boundaries/ constraints of system must be defined
2. systems behavior in terms of its response to disturbances from environment must be predictable in terms of its measurable parameters
- rules- laws used to describe how system works and generally require a "theory" which uses equations to describe behavior of systems and its boundaries in terms of input parameters - NO THEORY = NO VIABLE MODEL

14

History of Factory Designs

- no factories early on - needed factories b/c materials made so strong that man power cant cut - need machines
- 1st is job shop
2nd is flow shop (moving assembly line)
3rd is TPS

15

Economy of what? for each factory

- job shop - economy of collected processes
- flow shop - economy of scale
- TPS - economy of scope

16

What Ohno did for Toyota

- changed final assembly into mixed model final assembly line
- flex. and leveling - smoothing of prod. - demand
being smoothed
- conveyor driven lines converted to self-balancing sub assembly lines
- cellular manufacturing
- setup reduction / SMED
- integrated quality - 7 tools and 6 sigma

17

Kanban

Inventory and production control - JIT

18

Kaizen

continuous improvement

19

How does Final Assembly operate

- operated with Takt Time and operates on a MO CO MOO basis

20

Poke Yokes

single machine tools used within built-in devices to check parts

21

decouplers

device between machines designed to assist standing, walking workers producing parts in manufacturing cells
- SUSTAINS PART FLOW

22

4 terms of lean engineering: Level

final assemble line (working with forecasts to make this line to level demand)

23

4 terms of lean eng: Balance

what happens in the sub-assembly and manufacturing cells

24

4 terms of lean eng: sequence

what happens to stuff when it goes from supply chain to final assembly

25

4 terms of lean eng: synchronize

if something stops on final assembly, it stops also at sub-assembly. same with starting back up

26

Takt Time Rule

-level and balance the man. system - make final assembly mixed model - cells produce daily demand - sequence and synchronize
TT = hours available in a day / DD
DD = (# you make/month) / (# days you work/month)
PR = production rate = 1 / TT
TT for final assembly = (Avail hrs/shift)/(available DD/shift)

27

Self Balancing Sub Assembly Rule (OPF Rule)

- redesign subassembly lines into U-shaped SBSC's that operate flexibly with OPF to match final assembly needs
- MO CO MOO (OPF with defect prevention

28

Cell Design Rule (Lean Shop Rule)

MTij <= NCT where NCT = TT(1-allowance)
- the machine tools are single cycle automatics
- Cycle Time = Manual Time + Walking time
-dont add in machining times!
- every part that goes through cell goes through with same CT

29

SMED Rule

-Shingo
-setup time reduction to where its equal to or less than CT
- SMED - less than 10 minutes
1. determine whats happening now
2. separate internal from external elements (external = you can do while machine is running)
3. shift internal to external
4. eliminate adjustments

30

Kanban Rule

K = (DD X L + SS) / a
- DD is daily demand
- L is lead time
- SS is safety stock
- a is # of units in container
- K is # containers in Kanban Length
Ka = inventory in a single link
- for a link: Ka = L X DD = WIP
- for a system: WIP = TPT X PR
So sum of lead times for series of links = TPT for system
- all the inventory supplying the OPF is in these Kanban lengths - not 0 inventory (its in the kanban lengths - its in the control of the ppl that use it)

31

What did Ohno do with the cell design rule?

disconnected processing time from the schedule

32

Toyota's 5 R's for reducing pollution

refine
reduce
reuse
recycle
retrieve energy