ME503 FINAL QUESTIONS AND VERIFIED ANSWERS
Batch & Queue (Mass Production) - Answers - A method of processing where material
is accumulated into a lot and pushed through the process independent of demand or
requirements.
Features:
Low cost -> Low sell price
Flexibility to make many products
Negatives:
High WIP
Lot Delays
High transportation
Assembly Line Production - Answers - Arrangement of workers, machines, and
equipment in which the product being assembled passes consecutively from operation
to operation until completed.
Features:
Less transportation
Dedicated machines for one product
Low WIP
Negatives:
Bottlenecks
Quality control problems
Flow production - Answers - Large-scale production of a standard product, where each
operation on a unit is performed continuously one after the other, usually on a
production line
Features:
Minimal transportation
Shortens cycle time
Respond to fluctuation in demand
Achieve Flow Structure - Answers - 1. Small-lot production
2. Design to handle demand fluctuation
3. Supermarket system & kanban
4. Schedule control and JIT
5. Leveled Production
Supermarket System - Answers - -Buy what is needed, when needed
, -Stock replenished based on how it is removed
-Stock pulled based on demand
Schedule Control - Answers - Product is scheduled to be made on time
Load Control - Answers - Product can in fact (planned and capacity available) be made
Production Planning - Answers - Master Schedule (long term)
-annual reviews
Intermediate Schedule (monthly)
- unofficial schedule
Detailed Schedule (week, couple days)
-projected daily #'s
Production Leveling - Answers - The effort that the entire plant, not merely the
manufacturing
department, exerts when matching internal capability to the
actual mixed-model demand presented by Toyota's dealers
Benefits:
Flexibility in customer demand
Balance of labor and machine use
Smooths demand of upstream processes
Improving Operations - Answers - 1. Improve human motions
2. Improve machine motions
3. Mechanize human motions
4. Integrating waiting and (non-personal) margin allowance
5. Machine layout and T/M efficiency
6. Multi-machine T/M handeling
7. Multi-process T/M
8. Single minute exchange of dies (SMED)
Setup/Changeover - Answers - The process of changing the settings/dies/molds in
a machine to switch from manufacturing one product to another
Basic/common steps in setup of operations - Answers - 1. Preparations 30%
2. Mounting and removing 5%
3. Measurements, settings, and calibrations 15%
4. Trial runs and adjustments 50%
Benefits of reducing changeover time - Answers - - Increase effective capacity
- Shorten lead time
-Eliminate overproduction
Batch & Queue (Mass Production) - Answers - A method of processing where material
is accumulated into a lot and pushed through the process independent of demand or
requirements.
Features:
Low cost -> Low sell price
Flexibility to make many products
Negatives:
High WIP
Lot Delays
High transportation
Assembly Line Production - Answers - Arrangement of workers, machines, and
equipment in which the product being assembled passes consecutively from operation
to operation until completed.
Features:
Less transportation
Dedicated machines for one product
Low WIP
Negatives:
Bottlenecks
Quality control problems
Flow production - Answers - Large-scale production of a standard product, where each
operation on a unit is performed continuously one after the other, usually on a
production line
Features:
Minimal transportation
Shortens cycle time
Respond to fluctuation in demand
Achieve Flow Structure - Answers - 1. Small-lot production
2. Design to handle demand fluctuation
3. Supermarket system & kanban
4. Schedule control and JIT
5. Leveled Production
Supermarket System - Answers - -Buy what is needed, when needed
, -Stock replenished based on how it is removed
-Stock pulled based on demand
Schedule Control - Answers - Product is scheduled to be made on time
Load Control - Answers - Product can in fact (planned and capacity available) be made
Production Planning - Answers - Master Schedule (long term)
-annual reviews
Intermediate Schedule (monthly)
- unofficial schedule
Detailed Schedule (week, couple days)
-projected daily #'s
Production Leveling - Answers - The effort that the entire plant, not merely the
manufacturing
department, exerts when matching internal capability to the
actual mixed-model demand presented by Toyota's dealers
Benefits:
Flexibility in customer demand
Balance of labor and machine use
Smooths demand of upstream processes
Improving Operations - Answers - 1. Improve human motions
2. Improve machine motions
3. Mechanize human motions
4. Integrating waiting and (non-personal) margin allowance
5. Machine layout and T/M efficiency
6. Multi-machine T/M handeling
7. Multi-process T/M
8. Single minute exchange of dies (SMED)
Setup/Changeover - Answers - The process of changing the settings/dies/molds in
a machine to switch from manufacturing one product to another
Basic/common steps in setup of operations - Answers - 1. Preparations 30%
2. Mounting and removing 5%
3. Measurements, settings, and calibrations 15%
4. Trial runs and adjustments 50%
Benefits of reducing changeover time - Answers - - Increase effective capacity
- Shorten lead time
-Eliminate overproduction
