IOE 425 Exam 1 Study

  1. What are the 8 wastes?
    • Remember DOWNTIME
    • Defects
    • Over-production
    • Waiting
    • Non-utilized Talent
    • Transportation
    • Inventory
    • Motion
    • Extra Processing
  2. Define defects
    Anything that does not meet establish criteria
  3. Define over-production
    Doing more than the customer requires or providing a service that is not really needed
  4. Define waiting
    Elapsed time between processes when no work is being done
  5. Define transportation
    Unnecessary movement of material or product
  6. Define inventory
    Any time inventory does not match "need"
  7. Define motion
    Unnecessary movement by people; multiple hand-offs, ergonomics
  8. Define extra processing
    Adding unnecessary steps to a process; redundancies between processes
  9. What are theĀ 3 M's
    • Mura
    • Muri
    • Muda
  10. Define Mura
    • Waste of inconsistency/unevenness
    • i.e. irregularities in volume
  11. Define Muri
    • Waste of unreasonableness/overburden
    • i.e. heavy physical or mental burden
  12. Define Muda
  13. Given a goal fill in the 6 levels of the visual factory

    GOAL:Ensure that car lights are turned off when engine is shut off
    • level 1 [share information]: Include instructions in driver's manual
    • level 2 [share standards]: Label placed on car dashboard to instruct driver to turn off lights
    • level 3 [build standards]: "Switch Off Lights" visual indicator comes on dash when engine turns off
    • level 4 [warn about abnormalities]: Warning buzzer audio signal comes on if lights are not turned off
    • level 5 [stop abnormalities]: Keys cannot be removed until lights are switched off
    • level 6 [prevent abnormalities]: Lights are automatically switched off when car engine turns off
  14. Give some visual workplace examples
    • Shadow board
    • Production/control boards
    • Pallet/item drop off area
    • Traffic lights
    • Pictures of final product
    • Color coding
    • Costumes or uniforms
  15. What are the 5 S's?
    • 1. Sort
    • 2. Set (in order)
    • 3. Shine
    • 4. Standardize
    • 5. Sustain
    • 6. (Safety)
  16. What is a value stream map
    • Visual representation of a value stream
    • Helps reveal waste and problems with flow
    • Establishes a common language to document processes
    • Provides a blueprint for improvement
  17. Define Cycle Time
    Time between two products produced by a certain process step
  18. Define Process Time (P/T)
    total tome a process takes from start to finish
  19. Define Changeover Time (c/o)
    Time required to switch from producing one product to another or change from one type of serve to another
  20. Define Lead Time (L/T)
    The time it takes one "piece" to move through the entire value stream from start to finish (total elapsed time).
  21. What does Takt mean?
    pace, or beat
  22. Define Takt Time
    How often one part/unit should be produced based on rate of sales (demand)
  23. What is total cycle time
    total supply chain time from receipt of raw material to final delivery to the customer
  24. Define total lead time
    The time required to transform a product from raw material to a finished product/service delivered to the customer
  25. Why is flow important?
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IOE 425 Exam 1 Study
IOE 425