Lecture 13 - 🌟Mockup-Exam Flashcards
(35 cards)
What are three advantages and three disadvantages of digital shop floor meetings?
What are the advantages and disadvantages between chase and level? (4)
Production planning strategies used to match production with demand.
chase
- Uneven workload
- Reduced inventory in case of wrong forecast
level
- High inventory,
- but even workload
List Ishikawa’s 7 tools of quality control
(Basic Quality Tools)! ⛵️
S catter Diagram
C heck Sheets
H istogram
F ishbone Diagram
F low Charts
P areto Analysis / Chart
C ontrol Chart
What is the bullwhip effect? (3)
Increasing variability of demand and orders in a supply chain.
Leads to higher costs and inefficiencies. Caused by factors like
- forecasting errors,
- order batching,
- inventory practices,
- lead time variability.
What is Andon?
- System which notifies of a process Problem
- managerial, maintenance, and other workers
Imagine you order a BigMac but without pickles at McDonald’s. Where is the customer-order decoupling point (CODP) for your order in the McDonald’s store?
Raw material inventory
Which formula would you use to calculate waiting times in front of a ticket office?
Little’s law
___
L=λ⋅W
Where:
- L - is the average number of items in the queue,
- λ - is the average arrival rate of items to the queue, and
- W - is the average time an item spends in the queue.
Find the design capacity when ..
- utilization = 72%
- actual output = 36 trucks per day.
U=C/E
Where:
- U - utilization (Nutzung)
- C - design capacity
-
E - effective capacity
___
50 trucks per day
In planning and control we differentiate demand ..
- dependent
- independent
Which statements is false?
Once the dependent demand is known, the independent demand can be determined.
Which problems in a factory would you address first?
Overburdened processes
Key principles of Just-in-Time (JIT) (3)
One-piece-flow
Moving a product through every step of the process without grouping it into a batch
Takt Time
The rate at which goods need to be produced to meet customer demand
Pull System
Products are pulled into production as they are needed or requested by customers (no overproduction)
Describe four critical operational hurdles/challenges regarding creating a profitable remanufacturing business?
- Quality Assurance and Standardization
- Supply Chain Management (sourcing used products, acquiring replacement parts)
- Regulatory Compliance and Environmental Standards
- Reverse Logistics and products (cores) Acquisition
Would you recommend implementing a JIT strategy based on consumption-driven production? (4)
Yes, implementing a JIT (Just-In-Time) strategy based on consumption-driven production (pull system) would be advisable. This approach helps, ..
- minimize excess inventory (no overproduction),
- reduces waste, (One-piece-flow: Moving a product through every step of the process)
- ensures products are delivered to consumers at their peak freshness.
cross-country ski - What kind of forecast component is this? Provide an idea of how you would forecast the demand one month after the Olympics? (2x2)
Saisonal Peaks Components
Olypmics can be classified as an foreseen event or external factor, this is often referred to as a “spike” or “shock” to demand.
To forecast demand, you can use a combination of quantitative and qualitative forecasting methods:
- Analyze historical sales data,
- apply statistical methods,
- gather insights from sales and marketing teams,
- consult with key stakeholders.
What demand pattern does exist, within forcasting? (4)
- Cyclical components
- Seasonal peaks components
- Trend components
- Random variation (or residual variation)
Give 3 Quantitative forecasting methods (examples)
🐽🚤🟰
- Näive approach
- Moving averages
(weighted moving average) - Exponential smoothing
__ - Trend projection
- Causality model – linear regression
- Hybrid forecasting methods with fuzzy, probabilistic, and neural network methods.
Give me 3 Qualitative forecasting methods complement quantitative techniques.
- Market Surveys,
- Input from sales and customer service,
- Delphi Method,
- Intuition of forecasters
- Scenario Planning,
One of the 7 wastes in Lean is “inventory”. Should inventory always be sought eliminated? (2)
The key is to strike a balance between having enough inventory to meet customer demand and avoiding excess or unnecessary stockpiles.
Two basic inventory reorder systems:
- Reorder Level System
- Cyclical Review system
Why do we carry inventory? (5)
- To meet demand
- Protection against stock-outs
- Financial reasons
(e.g., bulk discounts or seasonal price variation) - Flexibility
- Process constraints
(e.g., minimum order or shipment levels, minimum processing levels)
Problems related to holding inventory (5)
Covers up errors in the system
- Ties up working capital
- Needs space
- Must be managed
- Is prone to damage, theft, and obsolescence
A factory has problems with throughput times and bottlenecks.
Could Process Mining be a viable technique to solve the problem? Why/why not? (5)
Process Mining can bring, ..
- Visibility into Processes
- Identifying Bottlenecks
- Root Cause Analysis
- Optimizing Workflows
However it is not a standalone solution, it should be
- complemented by a broader change management strategy,
- involving collaboration etween different stakeholders.
Competitive Capabilities in Manufacturing (4)
Operational Efficiency
- Supply Chain Management
- Cost Efficiency
Product Excellence
- Customization and Personalization
- Quality Control
Innovation and Adaptability
- Speed to Market
- Flexibility and Agility
- Innovation
Sustainable Growth
- Global Presence
- Compliance and Regulation Management
- Strategic Partnerships
Manufacturing Layouts (4)
Process Layout (Functional Layout)
- Description: Similar machines or operations are grouped together.
- Use Case: Ideal for job shops or facilities with diverse product types.
Product Layout (Line Layout)
- Description: Production process organized in a linear fashion with sequential workstations.
- Use Case: Suitable for high-volume production of standardized goods in assembly lines.
Cellular Layout (Cellular Manufacturing)
- Description: Machines and workstations grouped into cells based on similar tasks or processes.
- Use Case: Promotes efficiency, particularly for small-batch production.
Fixed-Position Layout
- Suitable for large products that cannot be moved during manufacturing.
- Use Case: Common in shipbuilding, construction, and aerospace manufacturing.
___________ ___________ ___________ ___
Hybrid Layout
- Description: Combines elements of different layouts for optimized efficiency.
- Use Case: Provides flexibility and efficiency by adapting to varying production needs.
Functional Layout with Assembly Lines:
- Description: Functional areas organized in a process layout, with assembly lines for final assembly.
- Use Case: Balances flexibility in component manufacturing with efficiency in final assembly.
Flexible Manufacturing System (FMS)
- Description: Involves computer-controlled machines and automated material handling for small-batch production.
- Use Case: Combines aspects of cellular manufacturing and automation for flexibility.
Meeting a doubling of demand in a short timeframe requires strategic planning and efficient execution. Suggest concrete and realistic ways to increase capacity to meet the demand surge. (3)
Operational Efficiency and Capacity Optimization
- Capacity Analysis
- Invest in Technology and Automation
- Expand Production Lines
- Extended Operating Hours
___ - Inventory Management
- Lean Manufacturing Practices
- Facility Expansion
- Collaborate with Third-Party Manufacturers
Workforce Development and Expansion
- Cross-Train Employees
- Workforce Expansion
- Investment in Training and Development
Supply Chain Collaboration
- Supplier Collaboration
