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New Material left off of INSY 3020 final quizlets
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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"
Standard Time
Determine Allowances
= Normal Time * (1+Allowances)
Staffing
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.
Line Balancing
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)
Work
the displacement of a mass or object
General Moves
moved freely through space
controlled moves
movement restricted; attached or in contact
tool use
using common hand tools
Each of the predefined sequence models has a different set of
phases
Sequence models are structured into _______ used to what?
phases
to describe the action performed.
Cycle Time
the average time between the start of production of one unit and the start of production of the next unit of production.
Takt time
the rate at which a finished product needs to be completed in order to meet customer demand.
available time/customer demand
Value Added:
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 . . . "
Optimal
lowest cost, highest quality, most reliable, .... Takt Time.
Produce value
manufacture a product, service a customer, ... Value Added
Lean Manufacturing originated with
the toyota motor corporation
heijunka
Level out the work load
work like the tortoise, not the hare
Muda
"futility; uselessness; wastefulness"
seven types
Operation Purpose
Questioning Attitude:
Never be afraid to ask: "Why are we doing this?"
Part Design
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
PBS
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?
NO
Transportation
- 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."
Soichiro Honda
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
inverse
low production
1 - 100 units/yr
Medium Production
100 - 10,000 units/ye
High Production
10,000 - +1,000,000 units/ye
Jidoka
Poke Yoke
BakaYoke
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
Direct Work
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
handbooks
old school standard data
- Expensive
- Information may be available on "pay" web-site
Old school standard data
• Handbooks & Sliders
• Nomograms
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
Drilling
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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