Lean Systems Applications And Case Studies In Manufacturing Service And Healthcare 1st Edition Elizabeth A Cudney ,Sandra Furterer ,David Dietrich - Solutions

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In your own words, describe three critical success factors and how they are influential in the development of Lean workshops.
Name the phase where each of the following tasks belong (assessment, preparation, execution, and follow-up):a. Giving a presentation to the management team on the workshop’s success.b. Defining SMART objectives.c. Identifying troublesome equipment or processes.d. Documenting the savings incurred
Which of the following is a SMART objective:a. Develop a manufacturing process by the third quarter of 2016.b. Improve the assembly line oven by 10% energy savings by August 13, 2016.c. Reduce WIP inventory in June.d. Increase throughput of the assembly line.
Name the four phases of a Kaizen workshop. Briefly describe the actions taken during each phase.
You are the manager of your local campus bookstore. After studying Hoshin Kanri, you have determined that you need a more transparent, clear strategic focus for the bookstore. You have identified four strategic goals for the bookstore in the near term: (1) grow the customer base, (2) lower
Define catchball. Give a specific example.
What is CFM? Why is it important in Hoshin Kanri?
How is Deming’s cycle different in Hoshin Kanri? Explain why it is different.
In Hoshin Kanri, a key step is to conduct an environmental analysis. What is an environmental analysis?
Describe the key steps for implementing an effective strategy.
What does the Hoshin implementation plan record, and how often should it be reviewed?
How is the purpose of showing the relationships in the Hoshin strategic plan summary matrix different from the Hoshin plan summary?
What is the purpose of the Hoshin plan summary? At what level in the organization should the Hoshin plan summary be developed?
What are the criteria for the metrics on your Hoshin strategic plan summary?
What is the key reason for showing the relationships in the Hoshin strategic plan summary?
What does the Hoshin strategic plan summary link? How are these linked? What information is provided in the Hoshin strategic plan summary?
What is the purpose of the annual review?
What is the purpose of the 1 year plan? What should be analyzed and considered when developing the 1 year plan?
Describe the six main steps of the Hoshin planning process.
What are the five levels of organizational needs? How do these relate to Maslow’s hierarchy of needs?
What are the five main steps for effective planning?
What are the two levels of Hoshin Kanri? Explain each level.
What does Hoshin mean?
Define Hoshin Kanri.
Where is the constraint?a, b,c, d,e, f, g?
Using the information in Figure 9.1, how many customers can be processed through the (a,b, c,d, g) routing during a 4-hour evening hair appointment?i. 24 ii. 48 iii. 12 iv. 32
Using the information in Figure 9.1 and what you have learned regarding TOC, what is the throughput time for the (a,b, c,d, g) routing?i. 35 minutes ii. 60 minutes iii. 50 minutes iv. 105 minutes
Explain why throughput is the most critical measurement. Give an example to support your explanation.
What is the heuristic measurement? Why was it developed?
What are the three measurements used to measure change in the system? Describe each measurement.
Why will maximizing the output and efficiency of every resource not necessarily maximize the throughput of an entire system?
Describe the five-step process that a change agent can use to strengthen the weakest link.
What is a bottleneck? Give a specific example.
What is a constraint? Define the three categories of constraints.
Define TOC.
Using the definition by Evans and Lindsay as a basis, create your own definition of a system.
You are the managing director of a large amount of convenience stores/fueling stations. You believe you can offer a competitive advantage over other convenience store competitors by offering faster service. Customer feedback indicates a demand to reduce the process to fuel an empty tank, acquire a
What is the least operator concept? Describe how it is used.
What information does the standard worksheet provide? How many standard worksheets should you develop?
What does the curved line on the standard work combination sheet represent?
What information does the standard work combination sheet combine?
Explain how standard work creates process repeatability.
What information does the process capacity table document?
What is the purpose of the time observation sheet? Describe the three key steps.
What is standard work-in-process? Why is it important?
Given the following information, calculate the takt time. The operation has an 8 hour shift, 20 minutes for break, 5 minutes for cleanup, 5 minutes for a daily stand-up team meeting, and a customer demand of 175 pieces per shift.
When calculating takt time:a. Include lunches and breaks in the available working time and reduce them afterward.b. Include lunches and breaks in the available working time but do not include planned machine downtime.c. Do not include lunches and breaks but include machine downtime as available
Define takt time. Give a specific example showing your calculation. Provide detailed information on the example such that anyone else could calculate the takt time.
To implement standard work, what are the three prerequisites?
Describe at least three benefits of standard work.
What are the three elements of standard work? Describe each element.
Define standard work.
You are the operations manager for a small company that assembles fans for computer systems. Your takt time is one fan assembly every 2 minutes with 480 minutes available for working per day. The assembly consists of a single injection-molded fan housing, a stainless steel shaft that is slid into a
How can poka-yoke concepts be used to design or redesign a product to be mistake proof during assembly or installation? Give a specific example.
Which type of poka-yoke detection device can be used to detect whether tasks are performed according to a specified sequence? Explain how this type of device works.
Describe the three main methods of poka-yoke detection devices.
What kind of systems are used to stop equipment when an error is detected? Why is this more effective?
What are the three methods to identify the proper poka-yoke for a situation?
What are the five situations where defects typically occur?
Describe at least five different types of errors. Give a specific example for each.
How can you prevent willful errors?
Describe at least five different types of errors. Give a specific example for each.
Give a specific example of a 100% inspection device.
How is source inspection different from judgment inspection and informative inspection?
Which of the following is the best way to error proof activities? Explain your answer.a. Corrective actionb. Preventive actionc. Containment actiond. Temporary action
Describe the three major inspection techniques that exist in the field of quality control.
Define poka-yoke. Give a specific example.
Who is the founder of poka-yoke? What was the main idea behind the development of poka-yoke?
Management has determined that a safety stock of 8% should be kept at all times. It takes roughly 6 minutes to move inventory from cell A. Determine the number of kanbans needed.
A machining facility is developing a new factory layout for its standard part business. As a newly hired engineer, you are determining the amount of kanban cards needed between work cells. You start at cell B for the analysis. Cell B is required to produce 115 parts per hour. Each container that
Work as a team and map out an area for a small spaghetti diagram project. It is often helpful to target a work process that occurs frequently and can be easily tracked. Commonly used examples include restaurants, bookstores, coffee baristas, libraries, and convenience stores. Again, remember that
What does Kaizen mean?
What is the ideal batch size in a continuous flow operation? Why?
The kanban method is most closely associated with which of the following? Explain your answer.a. The elimination of non-value-added activities in the processb. The development of a future state process stream mapc. Making problems visible in a process, thus clarifying targets for improvementd. The
Compare the different characteristics between a pull system and a push system.
What is a spaghetti diagram? Why is it useful?
Why is it important to be product focused when determining the proper layout?
Name five elements that are characteristic of a good cell design.
Name at least five benefits of one-piece flow in a cellular layout.
What is the key to the JIT production system?
What is the philosophy of the JIT production system?
Describe heijunka.
The management philosophy of make all we can just in case we need it is an example of what kind of system?
Define a withdrawal pull. Give a specific example.
Define a pull system. Give an example of a pull system that you have experienced.
Describe continuous flow manufacturing. How is it different from traditional manufacturing?
Where was batch production first used?
Give an example of a necessary non-value-added activity.
You work for a major dishwasher company. You have received customer complaints centered around a long process changeover during dishwasher batch processing. Although you do not know of any specifics, you have heard rumors that your competitor has come up with a number of clever features that reduce
Explain the difference between PM and predictive maintenance.
What is autonomous maintenance? Give an example.
What is the initial focus of TPM?
Define OEE. How is OEE different from utilization?
What are the three categories of major equipment loss?
Define TPM. What are the three goals of TPM?
Why should mechanization be the final attempt to streamline setups? Describe at least two techniques for mechanization in detail.
Describe how adjustments can be eliminated.
List and describe the four techniques for streamlining internal setups.
Why is 5S important when streamlining the external setups?
While streamlining the setup operation what should be considered when developing the improvement plan?

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Lean Systems Applications And Case Studies In Manufacturing Service And Healthcare 1st Edition Elizabeth A Cudney ,Sandra Furterer ,David Dietrich - Solutions

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