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14 Cards in this Set

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5S
Sort(What is needed, Sort through, then throw it out!)

Set-In-Order(What must be kept, make it visible and self explainatory so everyone knows what goes where).

Shine(Clean everything that remains; Clean equipment, tools, and workplace to make them functional).

Standardize(Create daily check list to be completed each shift. Make 5S a part of daily work routine).

Sustain(Requires discipline, stick to the rules and make them a habit)
Visual Factory
Simple, public signals that give immediate understanding of a situation of condition.

Efficient, self regulating, and worker managed.

Examples include charts and graphs, Visual work instructions, Kanban cards, Color coding, Lines on the floor, Andon lights, Labeling, and Sign Boards.

Reduces waste of waiting, motion, overproduction, and defects.
Quick Changeover
Time between the last GOOD piece off the current run and the first GOOD piece off the next run.
Batch Reduction
It's necessary in order to reduce inventory, thus reducing lead time.

It also reduces waste of defects, overproduction, waiting, transportation, and inventory.
Point of Use Storage
Raw material, tools, supplies are all stored where they are supposed to.

Works best if vendor relationship permits frequent, on-time, small shipments.

Simplifies physical inventory tracking, storage, and handling.

Opportunity for inventory reduction.

Reduces waste of motion, waiting.
Standardized Work
Operations organized in the safest, best known sequence using the most effective combination of resources.

1. Break job down into essential elements.

2. Examine each element in detail.

3. Determine best and safest method for each based on fundamentals and data.

4. Establish and teach the student.

5. Sustain by attention and repetition.

6. Improve the standard when better method is found.
Lean Workforce Practices
Teams with rotation of highly specified jobs.

Cross trained and multi-skilled employees.

Continuous improvement philosophy.

Participatory decision making.

Reduces waste of not utilizing people's KSAs.
Quality at the Source
Source Inspection: Operators must be certain that products they pass to the next work station are of acceptable quality.

Inspection tools: Operators have the means to perform inspection at the source, before the pass it along.

Process quality, not inspection.

Reduces waste of defects, waiting, not utilizing KSAs, inventory, excess processing.
Poka Yoke
Examples include car lights beeping when left on, manhole cover design, clearence bar in parking garage.
Total Productive Maintenance
TPM permanently improves the overall effectiveness of all employees and creates an environment that encourages improvement efforts in safety, quality, cost, delivery, and creativity.

Goal is to minimize downtime due to breakdown maintenance and to maintain machines at peak performance.

TPM consists of a companywide equipment maintenance program that covers the entire equipment life cycle and requires participation by every employee.

Reduces waste of defects, overproduction, waiting, not utilizing people's KSAs, Inventory.
Pull System
A Method of controlling the flow of resources by replacing only what has been consumed.

It consists of Production based on actual consumption, Small Lots, Low Inventories, Management by sight, and Better Communication.

It Reduces waste of overproduction, inventory.
Kanban
It's a signal to Produce of Convey.

Japanese word meaning Card or Signal.

Includes What? Where? When? How Much?

It can include outside suppliers.
Cellular(Cell) Manufacturing
It links manual and machine operations into the most efficient combination to maximize value-added content while minimizing waste.

Designing the 5 Step Process:

Step 1: Group Products
Step 2: Assess Demand, Establish TAKT Time
Step 3: Review Work Sequence
Step 4: Combine Work in Balance Process
Step 5: Design ____ layout
TAKT Time
It = Demand Rate

It = Work Time Available/Number of Units Sold.