Chapter 7 - Productivity Analysis

Lean Thinking

“Making more than what can be sold” is considered as _____ waste.

a) waiting

b) overprocessing

c) overproduction

d) inventory

c) overproduction

“Redundant inspections” is considered as ____ waste.

a) waiting

b) overprocessing

c) overproduction

d) inventory

b) overprocessing

“A hospital has multiple bins for waste disposal, but they all look the same.” Choose a Visual Control Method.

a) Labeling

b) Signage

c) VWI

d) Production Boards

a) Labeling

“A new employee at a coffee shop takes much longer to prepare drinks because they are unsure of the correct ingredients.” Choose a Visual Control Method.

a) Labeling

b) Signage

c) VWI

d) Production Boards

c) VWI

In a busy manufacturing facility, workers often walk into restricted areas without proper protective equipment. Choose a Visual Control Method.

a) Labeling

b) Signage

c) VWI

d) Production Boards

b) Signage

Your team cleaned and organized the office last month, but now it’s messy again. Choose one of the 5S.

A) Sustain

B) Shine

C) Set in Order

D) Sort

a) Sustain

Your kitchen is cluttered, and you often struggle to find utensils while cooking. Choose one of the 5S.

A) Sustain

B) Shine

C) Set in Order

D) Sort

c) Set in Order

Which lean tool is used to map the flow of materials and information to identify waste in a process?

a) Kanban

b) 5S

c) VSM

d) Poke-Yoke

c) VSM

Which lean tool focuses on workplace organization through Sort, Set in Order, Shine, Standardize, and Sustain?

a) 5S

b) Visual Management

c) Kanban

d) One-Piece Flow

a) 5S

Which lean tool is a pull-based system that signals the need for production or replenishment?

a) 5S

b) Visual Management

c) Kanban

d) One-Piece Flow

c) Kanban

Which lean tool uses color-coded labels and visual worker instruction to improve process control and efficiency?

a) 5S

b) Visual Management

c) Kanban

d) One-Piece Flow

b) Visual Management

Which lean tool is designed to prevent errors before they happen by using mistake-proofing mechanisms?

a) 5S

b) Poke-Yoke

c) Kanban

d) One-Piece Flow

b) Poke-Yoke

Which lean technique involves additional safeguards or layers to ensure prevent defects from progressing further?

a) Andon

b) 5S

c) Kanban

d) One-Piece Flow

a) Andon

What are the 5 simple principles of lean production?

1. Value

2. Value Stream

3. Flow (product flow)

4. Pull

5. Perfection

*cycle repeats

What are the 8 forms of waste?

T - transportation

I - inventory

M - motion

W - waiting

O - overproduction

O - overprocessing

D - delay

S - unutilized skills

Lead Time

total time from order placement to delivery

What is the countermeasure to the following waste:

Transportation/Motion

1. enhance layout

2. Shorten transport distances

What is the countermeasure to the following waste:

Inventory

1. EOQ

2. Pull System

What is the countermeasure to the following waste:

Waiting

1. allocation of work

2. Flow

What is the countermeasure to the following waste:

OverProduction

1. Pull System

2. Appropriate EOQ

What is the countermeasure to the following waste:

OverProcessing

1. Value Stream Mapping

2. Eliminate & reduce NV-adding activities

What is the countermeasure to the following waste:

Defects/Rework

1. Root Cause Analysis to fix the root cause

2. Do NOT add Inspections

What is the countermeasure to the following waste:

Unutilized Skills

1. well-defined job descriptions

2. organized work schedules

3. know people and their capabilities

What’s the structure of the Lean Production System?

1. Customer Focus

2. Just-In-Time Production

3. Autonomation

4. Worker Involvement/Continuous Improvement

5. Elimination of Waste

What are the four keys to Eliminating Waste?

1. Just-In-Time Production

2. Autonomation (automation with a human touch)

3. Worker Involvement

4. Continuous Improvement

What is Just-In-Time Production?

production and delivery of exactly the required # of each component to the downstream operation just at the moment when the component’s needed.

What does Just-In-Time Production reduce?

reduces unnecessary inventory

What is a push system?

a system in which parts are produced at each station irrespective of the immediate need for those parts at the downstream station

In a push system, “Upstream stations ____ work to downstream stations”

Push

What is a pull system?

an order to make and deliver parts at each workstation in the production sequence comes from the downstream that uses those parts

In a pull system, “downstream stations ___ work from upstream stations”.

pull

What does a Kanban system do?

Enforces the pull system to avoid overproduction

What are the Two types of the Kanban system?

1. Production kanban (production card)

2. Transport Kanban (move card)

What is takt time?

the time needed to produce one part based on customer demand

what is takt time driven by?

demand

Takt Time formula

available time / customer request ; min / units

takt time vs cycle time vs lead time

takt time - pace required to meet demand

cycle time - time taken to complete one unit

lead time - total time from order placement to delivery

What is cycle time driven by?

process

What is the desired relationship between cycle time and takt time?

cycle time <= takt time

If cycle time > takt time, what happens?

bottlenecks and delays occur

If cycle time < takt time, what happens?

excess capacity or idle time

What does takt time help reduce?

overproduction; it aligns production with demand to avoid excess inventory

What is “Changeover”?

the amount of time it takes to change a piece of equipment between production of one item to the next

In lean ideology, is it preferred to have a quick or slow changeover?

quick

Why is a quick changeover the goal?

• Reduces inventory costs

• better chance of on-time deliveries

• more production flexibility

What helps decrease the changeover time?

SMED ; Single-Minute Exchange of Die

What does SMED stand for?q

Single Minute Exchange of Die

What is the goal of SMED?

to get all changeovers and startups down to 10 minutes

Under SMED, each step should be how long?

one minute or less

T/F : By reducing setup time, factors can greatly improve efficiency.

T

What are 3 effects of setup time reduction?

1. Reduce Lead Time

2. Reduce Buffer Inventory

3. Possibly Reduce Setup Staffing

What are the two types of elements you have to consider when doing setup time reduction?

1. Internal Setup elements

2. External Setup Elements

Internal Setup Elements can only be done when?

while the production machine is stopped

T or F: External Setup Elements require the machine to be stopped.

False

Motion Studies help minimize what?

the sum of internal setup elements times?

Steps to Perform SMED:

1. separate internal from external setup operations

2. Convert internal to external setup

3. standardize functions

4. use functional clamps or eliminate fasteners altogether

5. use intermediate jigs

6. adopt parallel operations

7. eliminate adjustments

8. mechanization

Usually inventory is seen as ?

waste

What is one-piece flow the opposite of?

batch processing

What is the focus of one-piece flow?

manufacturing of the product itself rather than the waiting, transportation & storage of product

What does one-piece flow help reduce?

• the amount of WIP

• cost (because eliminating waste)

What is Heijunka?

production leveling

What is the goal of Heijunka?

to reduce inventories, capital costs, manpower, and production time to a minimum

What are some requirements for Just-In-Time Production?

• on time delivery of components

• defect-free components & materials

• reliable production equipment

• workforce that’s cooperative, committed, & cross-trained

What are Just In Time’s 6 main concepts we learned via Lean thinking?

1. Takt Time

2. Dependable Supplier

3. Quick Change (SMED)

4. Kanban System

5. Setup Time Reduction

6. One-Piece Flow

What is Autonomation?

automation with a human touch

What are the 3 subsections of Autonomation?

1. Stop the Process

2. Error Prevention

3. Total Productive Maintenance (TPM)

What is Jidoka?

where machines are designed to stop automatically when something goes wrong

Under autonomation, you stop the process when what happens?

1. Defective parts are produced

2. Required quantity has been completed (to avoid overproduction)

T or F: Jidoka is a way to “Stop the Process” under Autonomation.

T

The 4 steps of Jidoka:

1. Discover an abnormality or problem

2. Stop the operation process

3. Fix the problem at hand

4. Discover the root cause to prevent further ideas

What’s the primary innovation of Jidoka?

examining a manufacturing issue in the middle of the process rather than at the end

What is an example of Jidoka?

Andon

Andon is a form of ______ ________.

visual management

What is Poka-Yoke?

a form of quality control that highlights defects automatically & eventually takes humans out of the equation

Why is Poka yoke invented?

invented bc of human error

What is Total Productive Maintenance?

lean tool used to prevent machine downtime within production

What is the goal of Total Productive Maintenance (TPM)?

to limit downtime as much as possible to increase production efficiency

TPM is an integration of two types of maintenance. What are they?

1. Preventative Maintenance

2. Predictive Maintenance

What does ‘Muda’ mean?

waste

What does OEE stand for?

Overall Equipment Effectiveness

What does OEE serve as?

a diagnostic tool to uncover inefficiencies, breakdowns, and sources of waste in production processes

OEE takes into account three factors.. what are they?

1. availability

2. Performance

3. Yield (aka quailty)

Goal of OEE is?

to maximize OEE to approach 100%,which indicates optimal machine performance & reliability

In a lean environment, an OEE score of ___ is often considered a world-class benchmark.

85%

T or F: Availability of machines tends to be lower when equipment is new (debugging phase) and when it ages.

T

Machine Performance will always be <= to ?

1

Machine performance symbol can either be?

U or P (U for utilization, P for performance… both mean the same)

What’s the machine performance equation?

U = P = Q/PC = # hrs actually done/total # of avail. hrs for machines

T or F: Utilization/Performance can be assessed only for a single machine

False — can also be for an entire plant

What are some reasons for poor utilization/performance?

• poor scheduling of work

• worker absenteeism

• low demand

Visual Management definition

a communication technique that uses visual aids to conv ey messages quicker

What are the 5 examples of Visual Controls?

1. Signage

2. Labels

3. Production Boards

4. Visual Work Instructions (VWI)

5. Color Coding

5S is what?

a structured program to implement workplace organization and standardization

1s - Sort

remove what’s not needed

2s - Set in Order

arrange essential items in order for easy access

3s - Shine

keep things clean and tidy

Benefits of 5S activity

• reduce non-value added activity

• improve floor space utilization

• reduce search time in navigating facility

What is standardized work?

a tool used to document current best practices, improve the standard, and ensure that the new standard becomes a baseline for improvement

What is Gemba?

When management goes to the factory floor to search and fix visible problems

Root Cause Analysis is what?

• a lean problem-solving method that aims to get to the root of a problem

• iterative process