New Material left off of INSY 3020 final quizlets

Terms in this set (68)

What are time standards based off of?

a fair days work

Fair Day's Work.

The amount of work that can be produced by a qualified employee when working at a normal pace and effectively utilizing their time where work is not restricted by process limitations.

Finding Standard Time

Measure Observed Time (OT)
Calculate "Normal Time"
Calculate "StandardTime"

Determine Allowances
= Normal Time * (1+Allowances)

reason for standard time

also know as work force planning : the number of workers required cannot accurately be determined unless the time required to process the existing work is known.

or production leveling : the correct number of workstations for optimum work flow depends on the processing time, or standard, at each workstation.

how much faster is establishing standards using most than when using MTM-1?

at least 5 times faster

MOST is used to analyze

work and to determine the normal time that it would take to perform a particular process /operation.

What are the measurements in MOST

Time Measurement Units (TMU's)

the displacement of a mass or object

moved freely through space

controlled moves

movement restricted; attached or in contact

using common hand tools

Each of the predefined sequence models has a different set of

Sequence models are structured into _______ used to what?

phases

to describe the action performed.

the average time between the start of production of one unit and the start of production of the next unit of production.

the rate at which a finished product needs to be completed in order to meet customer demand.

available time/customer demand

processing step that enhances a product or service before offering the product to customers

value after the step - value before the step

Non-Value Added:

a processing step that does not enhance the product
- Transport, Movement, Inventory, WIP, Inspection, Rework

Methods Engineering includes

designing, creating, and selecting the best methods, processes, tools, equipment, and skills to manufacture a product . . . "

lowest cost, highest quality, most reliable, .... Takt Time.

manufacture a product, service a customer, ... Value Added

Lean Manufacturing originated with

the toyota motor corporation

Level out the work load
work like the tortoise, not the hare

"futility; uselessness; wastefulness"

seven types

Operation Purpose

Questioning Attitude:
Never be afraid to ask: "Why are we doing this?"

Before we develop a method:
- Remember: "The most efficient process is one we are not doing."
- Always ask, "Make or Buy?"

What is the best design so it is easy to make?
- Design Engineers are not manufacturing engineers.

DFMA Guidelines

Minimize part count by incorporating multiple
functions into single parts.

Modularize multiple parts into single
subassemblies

assemble in open spaces, not in confined spaces. Never buy important components

Make parts to identify how to orient them for insertion

standardize to reduce part variety

Improving tolerances and specifications can reduce

cost due to inspections, scrap, and rework.

System Functional Decomposition

System -> Subsystem -> Assembly -> Subassembly -> Component -> Part

product breakdown structure

Manufacturing Sequence & Tools

Make or Buy?

• Rearrange or combine operations
- "The most efficient process is one we are not doing."
- Cam Tower Boring

• Manufacture near the net shape (minimize material removal)
- Casting (Die Cast/Lost Foam) - Injection Molding

Typical uses for a robot

die casting
forging
painting
welding
material handling

material handling

pick and place
palletizing

Humans excel in

perceiving patterns and making generalizations about them

ability to exercise judgement where events cannot be completely defined

ability to profit from experience and alter course of action

ability to perform fine manipulations, especially where misalignment seems unexpected

Machines Excel in

performing routine, repetitive, or very precise operations

doing many things at one time

ability to repeat operations very rapidly, continuously, and precisely the same way over a long period

Is transportation considered value added?

- Moving, storing, positioning, tracking.
- Insuring that materials get where they need to be
when they are needed.- Bar Codes

How much of the cost if getting a product to market is associated with material handling?

35% to 85% according to the Material Handling Institute

How does Production move?

Production flows like a river!

"Aim for a harmonious flow of work."

Poor layout can result in

major costs through increased travel time, increased material handling, etc.

what is the type of relationship between size and complexity

1 - 100 units/yr

Medium Production

100 - 10,000 units/ye

High Production

10,000 - +1,000,000 units/ye

Rejected

Fool proofing or idiot proofing

All indirect and expense work is a combination of four divisions

Direct work

Transportation

Indirect work

Unnecessary work & delays

Segment of the operation that discernibly advances the progress of the work
• Delivering Parts

Work Standards for Indirect Labor

We can apply IE Techniques to Indirect/Expense Labor
• Process Flow Chart
• Travel Chart
• Queuing Theory
• Benchmarking
- Ratios/ Key Performance Indicators (KPI)

Process Flow Charts/ Travel Charts: Key Concepts

Efficiency
• ValueAdded:processingstepthatenhancesa product or service before offering the product to customers
- Value Added= (Value after step) - (Value before step)
• Non-ValueAdded:aprocessingstepthatdoes not enhance the product
- Transport, Movement, Inventory, WIP, Inspection, Rework

Seven types of Muda

Transportation
inventory
motion
waiting
overproduction
over processing
defects

Types of Maintenance (Craft) in indirect labor cost

Equipment Service
- Welder, Millwright, Electrician,
Instrument/Controls Tech -> Multi-craft

• Die/Tooling/Machinist

• Tool/Setup

Where can we apply Work Standards?

Die/Tooling/Machinist

Tool/Setup

Where can we not apply Work Standards?

Equipment Service
- Welder, Millwright, Electrician,
Instrument/Controls Tech -> Multi-craft

Types of maintenance work

break down!!

planned work

preventitive/predictive

Maintenance Work-Typical Problems

Inadequate communication
• Unavailability of parts, tools, equipment
• Interference of production employees
• Overstaffing of the maintenance job
• Rework
• Improper planning
• Not unusual to find that the workforce is productive only 30-50% of the time

Material Handling/Forklift Direct Measurement

- Work Sampling
- Travel Chart/Layout
• Pareto Chart

What does standard data allow?

allows the development of a job without the use of a stopwatch or PDTS

Where Do You Get standard data?

• Build it yourself (History)
• Buy a Database
• Books, Handbooks, etc.
- Table/ Charts/ Nomograms

old school standard data

- Expensive
- Information may be available on "pay" web-site

Old school standard data

• Handbooks & Sliders
• Nomograms

"A diagram representing the relations between three or more variable quantities by means of a number of scales, so arranged that the value of one variable can be found by a simple geometric construction, for example, by drawing a straight line intersecting the other scales at the appropriate values."

Tabular Data for Machining

• Lathes, Drills, Milling Machines
- (Chip Producing Equipment)

• Critical Factors
- Material being cut (hardness)
- Type of tool
- Size of chip
- Feed Rate

Long and flexible tool

small cutting edge and rake face

long chip removal path

chip removal is often an issue

Fillet welding refers to

the process of joining two pieces of metal together whether they be perpendicular or at an angle. These welds are commonly referred to as Tee joints

Butt welding is

a welding technique used to connect parts which are nearly parallel and don't overlap.

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