When large jobs are divided into smaller tasks or each task became specialists in their assigned tasks, this refers to…
Specialization/Division of Labor
The heart of modern manufacturing are ________________ due to allowing any part of a certain type to be used in assembly.
Interchangeable Parts
What are the two major points for the Work Flow Principle?
1) Work is moved to the Worker
2) Work units flow smoothly through the production line
For 1), emphasis on TO the worker, not the worker moving to the work.
Workers on the assembly line completing tasks within a specific cycle time is called…
Line Pacing
What does line pacing help with?
1) Maintaining a particular production rate
2) Uniform Worker Contribution
What is a common machine that is used to implement pacing?
Mechanized Conveyors
What is the definition of a manual assembly line?
1) A process of multiple work stations, all in sequence
2) Humans conducting the work
What are two types of workstation design?
1) Standing Workstations
2) Sitting Workstations
What are standing workstations meant for?
1) Large Products & Major Appliances
2) Workers Require to Move around Station Area
What are sitting workstations meant for?
1) Smaller Products & Smaller Appliances
2) Reduces fatigue, improves comfort, precision and accuracy
Would the operation of changing/installing tires perform better with a sitting or standing workstation?
Standing Workstation
Operator needs to move around, needs area to remove the tire
What are the two major problems with Manual Work Transport?
1) Starving (Worker is idle due to the next step hasn’t arrived)
2) Blocking (A worker finishes a task, but cannot pass the unit to the next step)
Starving: Lack of parts, Blocking: Lack of Progression
What is the easiest way to fix starving?
Always have a part queued up, ready to go.
What are the three solutions to mitigate both starving AND blocking?
1) Storage buffers
2) Batch Movement
3) Individual Movement
Adding Storage Buffers between stations provides ________________ for incoming/outgoing work units and helps ensure a ________________ and minimizes ________.
- Temporary Space
- Continuous Flow
- Idle Time
________________ refers to work units being collected in batches before being moved to the next station.
Batch Movement
When work units are pushed manually by a non-powered conveyor or flat table, what is that manual method called?
Individual Movement
In individual movement, each station has space for what, and why?
1) Space for Incoming Units (to Avoid Starving)
2) Outgoing Units (to Avoid Blocking)
What are the three limitations of manual transport?
1) Significant work-in-progress (WIP) inventory
2) Unpaced lines
3) Lower Production Rates
Unpaced Lines implies they are working at their own speed.
What are the three types of mechanized work transport?
1) Continuous Transport
2) Synchronous/Intermittent Transport
3) Asynchronous Transport
In the context of Mechanized Work Transport…
What is the definition of Continuous Transport?
Using a continuously moving conveyor at a constant velocity.
In the context of Mechanized Work Transport…
What are two implementation methods of Continuous Transport?
1) Work units fixed to the conveyor
2) Work units removable from the conveyor
1) used for large/heavy products
2) used for small/lightweight prducts
In synchronous mechanized transport, how do all work units move?
Simultaneously in quick, discontinuous motions.
Requires tasks to be completed within a set time.
Mechanized synchronous transport is not common in what type of assembly lines? Where is its implementation ideal?
1) Uncommon in manual assembly Lines
2) Ideal for Automated Lines
1) Due to stress/risk of incomplete work
2) Due to consistent cycle time
