Industrial Engineering & Process Improvement Assessment Flashcards

A set of vocabulary flashcards covering Lean manufacturing, Six Sigma, Quality tools, OEE, Supply Chain, and EHS based on industrial engineering assessment notes.

TIMWOODS / DOWNTIME

Acronyms used to remember the 8 wastes in Lean Manufacturing, such as Transportation, Overproduction, and Waiting.

Value Stream Map (VSM)

A tool primarily used to visualize material and information flow to identify non-value-added steps in a process.

Seiton

The step in 5S that refers to setting items in order for easy access.

Overprocessing

A type of waste that occurs when more work or higher precision is applied to a product than the customer requires.

Kaizen event

A focused, short-duration improvement activity targeting a specific process.

Single-Minute Exchange of Die (SMED)

A methodology used to reduce setup or changeover time.

Kanban system

A tool used to visually manage work-in-progress and pull production based on downstream demand.

Cellular manufacturing layout

A layout where equipment and stations are arranged in the sequence of the process flow for a product family.

DMAIC Analyze Phase

The phase primarily focused on identifying root causes of defects or variation.

Pareto chart

A tool based on the $80/20$ rule, stating that a small number of causes account for most effects.

Process capability index (Cpk)

A metric that measures how well a process output fits within specification limits while accounting for centering.

Special cause variation

Assignable variation indicated by a control chart point falling outside the control limits.

5 Whys

A technique used to drill down iteratively from a symptom to a root cause.

Fishbone (Ishikawa) diagram

A diagram that organizes potential causes under categories such as Man, Machine, Material, Method, Measurement, and Environment.

Corrective action

In a CAPA process, this addresses the immediate root cause of the identified nonconformance.

ISO 9001 Clause 10.2

The clause regarding Nonconformity and Corrective Action that requires organizations to react to nonconformities and evaluate the need for action to eliminate root causes.

OEE (Overall Equipment Effectiveness)

A metric calculated as $\text{Availability} \times \text{Performance} \times\text{Quality}$.

Availability calculation

$$\text{Availability} = \frac{\text{Planned Production Time} - \text{Downtime}}{\text{Planned Production Time}}$$

Performance (OEE component)

A reflection of speed loss, comparing the actual output rate to the ideal or design rate.

MTBF (Mean Time Between Failures)

A key metric used for assessing equipment reliability.

MTTR (Mean Time To Repair)

A metric used to identify opportunities to improve maintenance response and repair efficiency.

Autonomous Maintenance

One of the 8 pillars of TPM where operators take ownership of basic equipment care such as cleaning, inspection, and lubrication.

Six Big Losses

TPM categories including Breakdowns, Setup/Adjustment, Small Stops, Reduced Speed, Startup Rejects, and Production Rejects.

Economic Order Quantity (EOQ)

A model that minimizes the combined total of ordering costs and holding costs.

Safety stock

Inventory held primarily to buffer against variability in demand and/or supply lead time.

Just-In-Time (JIT)

A production aim to produce and deliver exactly what is needed, when it is needed, in the amount needed.

Bullwhip Effect

The amplification of demand variability as orders move upstream from retailer to manufacturer to supplier.

Material Requirements Planning (MRP) inputs

The Bill of Materials (BOM), Master Production Schedule, and Inventory records.

OTIF (On-Time-In-Full)

A metric reflecting a supplier's performance regarding delivery timing and completeness.

HIRARC

An acronym for Hazard Identification, Risk Assessment, and Risk Control.

Hierarchy of Controls

A sequence of safety measures from most to least effective: Elimination, Substitution, Engineering Controls, Administrative Controls, and PPE.

ISO 45001

A standard for occupational health and safety management systems that integrates hazard identification and risk assessment into planning.

ISO 3864 and ISO 7010

Standards that primarily standardize safety signs, symbols, and colors.

Risk Level

Typically calculated as a function of $\text{Likelihood of occurrence} \times \text{Severity of consequence}$.

Takt time vs. Cycle time

If actual average cycle time (e.g., $55 \text{ seconds}$) exceeds takt time (e.g., $45 \text{ seconds}$), the line is a bottleneck and cannot meet demand.