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67 Cards in this Set
- Front
- Back
- 3rd side (hint)
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What is the process for systematic layout planning? |
1) Determine requirements 2) Analyse material flows 3) Activity relationship chart 4) Activity relationship diagram 5) Determine space requirements 6) Construct space relationship diagram 7) Adjustments and allowances 8) Block layout |
Activity relationship chart Space relationship diagram Block layout |
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What is Production Flow Analysis? |
Develop a part/machine matrix and binary sort rows and columns. Repeat until no changes and then group parts by cluster. |
Binary sort matrix |
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Define "Fixed Layout" |
Everything comes to where the product is made |
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Define "Process/Functional Layout" |
All tasks that involve the same activity take place in the same area |
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Define "Process/Line Layout" |
Work stations are equipped to perform specific functions along an assembly line |
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Define "Cellular Layout" |
Units flow through stations. But stations are more flexible than standard production lines |
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What are the equations and parameters of the exponential model for failure probability? |
For centre of bathtub curve |
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What is the "Performance Rate"? |
Measures losses in effectiveness due to slow production |
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What is the "Availability Rate"? |
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What is the method study procedure? |
Select Record Examine Develop Define Install Maintain |
7 steps |
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What are the 5 S's? |
Sort Set in order Standardise Self-discipline Shine |
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Define "Poka-Yoke" |
Design machines and processes to that it is very hard to make mistakes |
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Define "Andon Chords" |
Allow workers to stop production as soon as they notice a defect or issue |
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Define "Kaizen" |
Focus on continuous improvement, including employees quality circles |
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What are Ohno's 8 wastes? |
Transportation Inventory Motion Waiting Over-processing Over-production Defects Skill |
Tim Woods |
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What are the elements of the house of lean? |
Reduction of waste Worker involvement Just-in-time production Autonomation Customer focus |
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How do you find the required rest breaks for a worker? |
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What is Method Study? |
The systematic recording and critical examination of current and proposed ways of doing work. |
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How do we calculate the reliability of a part after a burn in time? |
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What is the hazard Rate? |
The probability of the part surviving for ◇t given that it has already survived for time T |
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How do you evaluate layout efficiency? |
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How is standard time defined in work measurement? |
Basic time + allowances = standard time |
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What is the quality Rate? |
Measures losses due to production of defective parts |
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How do you calculate a confidence interval for work measurement times? |
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What are the advantages of Activity Sampling? |
Less time, lower cost Less demanding of subject Less tedious for observers |
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What are the disadvantages of Activity Sampling? |
Not as accurate as direct time study Not practical for a single subject Discover less useful information "Strange" methods may make workers suspicious |
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How do you determine the number of samples for Activity Sampling? |
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How do you calculate confidence intervals for samples for Activity Sampling? |
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What is Activity Sampling? |
A statistical technique for determining the proportion of time spent by subjects in various defined categories of Activity. |
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What is PMTS? |
PMTS assigns basic/normal times taken to perform basic motions, take from MTM-1. Highly detailed Quantitative and objective Comparative |
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What is the definition of the learning curve and the learning Rate? |
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How do you determine the number of samples for time Study? |
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What are the advantages of supply network collaboration? |
Efficiency Flexibility Lower contract costs Mutual learning Long term stability |
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What are the disadvantages of supply network collaboration? |
Communication cost Risk of oppurtunism Reduced options Information leaks |
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What is the difference between lean and agile supply chains? |
AGILE innovative products Fast response LEAN Functional products Low cost, high use |
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How do you choose where to locate a new facility? |
1) Centre of gravity method 2) Load-distance method |
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What are the key considerations before outsourcing production? |
Is the activity strategically important? Can we improve our performance? Is the activity new and innovative? What level of IP protection exists? |
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Compare MRP and JIT |
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What are the limitations of MRP ? |
Assumes infinite capacity Requires fixed batch sizes and lead times No feedback Relies on forecasts Push production is inherently limited |
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Define Takt Time |
(Available demand)÷(demand per period) = T The index time of the line |
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Calculate the minimum number of stations |
(Total processing time) ÷ (takt time) |
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Define the line balancing loss |
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How do you minimise makespan with 2 machines? |
Johnson's Rule Starting from the shortest processing time on either machine: Assign jobs with short processing times on m/c 1 to the earliest slot Assign jobs with short processing time on m/c 2 to the latest slot |
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How do you minimise the number of tardy jobs? |
Moore's Algorithm Arrange jobs by earliest due date; Find the first tardy job; Remove the job before it with the longest processing time; Repeat until no tardy jobs remain. |
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What is the exponential forecast updating formula? |
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How do you calculate the moving average forecast? |
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How do you calculate the production schedule with variable quantity and time period? |
The Least Unit Cost Heuristic Work out how many periods to order for by calculating the holding cost and ordering cost for them all and selecting the lowest cost per unit option. |
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What are the underlying assumptions of EOQ? |
Known and constant demand Known and constant lead times No supply side restrictions Known and constant holding cost Known and constant ordering cost Items are independent |
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What is the formula for EPQ? |
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What is the formula for EOQ ? |
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How does little's law apply to inventory management? |
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What strategies can be used to manage demand to suit capacity? |
1) Promotions and Offers 2) Counter Cycle Products 3) Lead Time Variation |
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What is the chase demand approach to capacity management? |
Capacity is increased and decreased to cope with forecast levels of demand. Attempts to minimise inventory holding |
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What is the level capacity approach to capacity management? |
Fixed level of capacity Level set to cope with maximum expected demand |
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What events can lead to reductions in capacity? |
Bottlenecks Machine set ups Breakdown Quality losses Slow running Idling |
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What are the four main challenges in capacity planning? |
1) must rely on imperfect forecasts 2) requires large, irreversible investment 3) decisions can have political implications 4) capacity is a soft constraint, it can stretched and shifted |
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What is the definition of capacity? |
The maximum value added to a product or service during normal production |
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What is the formula for visual angle? |
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What are the formulas for Illuminance? |
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How do you minimise the replacement cost for a part or machine? |
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How do you calculate the reliability of series and parallel systems? |
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What are the limitations of the Northwest Corner method? |
Heuristic Sensitive to starting point Complex for multiple items No transport variations Fixed supply and demand |
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How do you minimise the average tardiness? |
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Define the 3 measures of forecasting error |
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When is the fixed time period inventory model preferred? |
High cost of monitoring stocks Multiple orders from the same supplier Fast moving, low cost items |
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When is the fixed order quantity inventory model preferred? |
Highly variable demand Important items High cost items as average inventory is lower |
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What is the total cost of age based preventative replacement? |
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