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Untitled Deck Flashcards

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1
Q

What does TIMWOODS stand for in Lean Manufacturing?

A

T=Transportation, I=Inventory, M=Motion, W=Waiting, O=Overproduction, O=Over-processing, D=Defects, S=Skills (underutilized)

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2
Q

What is the Transportation waste in TIMWOODS?

A

Any movement of people or inventory that does not add value. Transporting product between processes adds cost but no customer value. Can cause damage and quality deterioration.

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3
Q

What is the Inventory waste in TIMWOODS?

A

Goods produced for which there is no customer demand. Excess inventory increases lead times, consumes floor space, delays problem identification. Work in Progress (WIP) is a direct result of overproduction.

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4
Q

What is the Motion waste in TIMWOODS?

A

Unnecessary movement related to ergonomics: bending, stretching, walking, lifting, reaching. These are also health and safety issues. Move material as short a distance as possible.

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5
Q

What is the Waiting waste in TIMWOODS?

A

Whenever goods are not moving or being processed. Idle people waiting for inventory indicates plant imbalance. Link processes together so one feeds directly into the next.

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6
Q

What is Overproduction waste in TIMWOODS?

A

Manufacturing items before they are required (just in case). Highly costly, prohibits smooth flow, degrades quality and productivity. Creates excessive lead times and high storage costs. Produce to order (just in time) not for inventory.

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7
Q

What is Over-processing waste in TIMWOODS?

A

Useless process steps that can be eliminated without harming end product value. Using expensive high-precision equipment where simpler tools would work. Often results in poor plant layout.

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8
Q

What is the Defects waste in TIMWOODS?

A

Quality defects resulting in rework or scrap are a tremendous cost. Opportunity to reduce through employee involvement and continuous process improvement (CPI). Use mistake-proofing to eliminate errors.

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9
Q

What is the Skills waste in TIMWOODS?

A

Organizations use staff for physical work but forget they have brains. Only by capitalizing on employees’ creativity can organizations eliminate the other seven wastes and continuously improve.

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10
Q

What is the RPN formula in FMEA?

A

RPN = Severity × Occurrence × Detection. Range is 1-1000. Severity is weighted most heavily.

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11
Q

What does FMEA stand for?

A

Failure Modes and Effects Analysis. Systematic method to identify product, process, or system failures early in design. Goal is to design in quality and reliability early in development cycle.

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12
Q

What are the 4 types of FMEA?

A

1) Design FMEA (design-related failures), 2) Process FMEA/PFMEA (process-related failures), 3) System FMEA/SFMEA (system-related failures), 4) Machinery FMEA/MFMEA (machinery-related failures)

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13
Q

What does QFD stand for?

A

Quality Function Deployment. A matrix-based methodology to convert customer needs into engineering specifications. Basic matrix is the House of Quality (HoQ).

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14
Q

What is the objective of QFD?

A

Designing for customer satisfaction the first time, every time. Understanding the WHATs (customer requirements) before worrying about the HOWs (engineering specs).

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15
Q

What are the 3 QFD collection methods for customer requirements?

A

1) Observations, 2) Surveys, 3) Focus groups (7-10 customers, multiple sessions, open-ended questions)

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16
Q

What is SLA in rapid prototyping?

A

Stereolithography. Laser solidifies resin layer by layer. Uses moveable elevator platform to lower platform and cover previous layer with new resin. Parts often require post-curing in separate oven.

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17
Q

What is FDM in rapid prototyping?

A

Fused Deposition Modeling. Uses a roll of filament that is extruded over a table to build layers upon layers to create parts.

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18
Q

What is SLS in rapid prototyping?

A

Selective Laser Sintering. Similar to 3DP but uses a laser to fuse powder together instead of adhesive.

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19
Q

What is 3DP in rapid prototyping?

A

Three Dimensional Printing. Uses an inkjet head that sprays adhesive onto powder. Makes thin layers and a roller brings fresh powder when needed.

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20
Q

What is SGC in rapid prototyping?

A

Solid Ground Curing. Uses photosensitive resin and UV source through a photomask. Vacuum sucks up uncured resin, wax is applied as support, then mill cleans and smooths surface. Process repeats.

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21
Q

What is LOM in rapid prototyping?

A

Laminated Object Manufacturing. Material comes in a roll (usually paper). Laser traces pattern onto paper and heated roller activates adhesive. Waste paper rolled onto separate roll.

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22
Q

What is LENS in rapid prototyping?

A

Laser Engineered Net Shaping. Uses laser to melt metal powder supplied coaxially through nozzle. Uses XYZ control system. Metal powder delivered via gravity or pressurized gas. Inert gas shields metal pool from oxygen.

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23
Q

What are the 3 major elements of Total Quality Development (TQD)?

A

1) Basic Concurrent Engineering (BCE), 2) Enhanced Quality Function Deployment (EQFD), 3) Quality Engineering using Robust Design (QERD)

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24
Q

What are the 3 major determinants of market share and profitability?

A

UNIT COST, QUALITY, and MANUFACTURING LEAD TIME

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25
What is Jidoka?
Intelligent automation or automation with a human touch. Automated process detects malfunctions/defects, stops itself, and alerts operator. Work stops immediately when problem occurs instead of after many defective products are made.
26
What is Andon?
Visual light board. Green = normal operation, Yellow = operator needs help, Red flashing = line has stopped.
27
What is Poka-Yoke?
Mistake Proofing. Use of automatic device or method that either makes it impossible for error to occur or makes error immediately obvious once it has occurred. Error-proofing prevents defects.
28
What is Heijunka?
Production leveling. Eliminates Mura (variation in demand/workload/flow). Japanese technique of achieving even output flow by sequencing very small production batches. Vital for Just In Time (JIT).
29
What is Just In Time (JIT)?
Inventory strategy where companies receive items only as needed in production, reducing inventory costs. Requires accurate demand forecasting. Parts produced on as-needed basis.
30
What are 3 JIT advantages?
1) Reduces cost by eliminating warehouse storage, 2) Spend less on raw materials (buy just enough), 3) Production runs stay short, easy to switch products
31
What are 2 JIT disadvantages?
1) If one supplier can't deliver on time, entire production shuts down, 2) Sudden order surge may delay delivery to clients
32
What is Kanban?
Signal board that communicates need for material and visually tells operator to produce another unit or quantity. Parts produced on as-needed basis.
33
What is Kaizen?
Continuous improvement. Main element is having people at all levels involved in improvement process. Allows improvements immediately rather than waiting for management approval.
34
What are the 10 Kaizen Principles?
1) Get rid of old assumptions, 2) Don't look for excuses, 3) Say no to status quo, 4) Don't worry about perfection-start now, 5) Doesn't cost money, 6) Fix problems now, 7) Good ideas flow when tough, 8) Ask why 5 times, 9) Seek wisdom from many, 10) Never stop doing Kaizen
35
What are the 5S disciplines?
1) Sort (remove unneeded items), 2) Set in Order/Straighten (arrange tools), 3) Shine/Sweep (keep clean), 4) Standardize (maintain first 3S), 5) Sustain (top-down ongoing support)
36
What is Sort in 5S?
Remove all items from workplace not needed for current operations. Leave only bare essentials. Target excess inventory, obsolete items, unneeded tools/equipment.
37
What is Set in Order in 5S?
Ensure tools needed for job are in place and easy to find, use, and return. Eliminate motion waste. Map work area, use color coding and visual controls.
38
What is Shine in 5S?
Keep everything clean and readily usable. Create cleaning inspection checklists. Daily cleaning and periodic deep cleans.
39
What is Standardize in 5S?
Method to maintain first 3S. Everyone must know exactly what they're responsible for and when/where/how to do it. Make 5S procedures unbreakable and habitual.
40
What is Sustain in 5S?
Top-down support of ongoing 5S process. Allocate time, create awareness, provide structure, show support, offer rewards/recognition, encourage training/participation.
41
What are U-Shaped Layouts in Lean?
Manufacturing cells where one operator can move single part through all steps. Requires less floor space, reduces material handling, less WIP inventory, shorter flow paths. Quality issues quickly visible. Operators can see and talk to each other.
42
What is Value Stream Mapping (VSM)?
Lean tool for identifying waste and improving productivity. Documents flow of information and materials through system. Assesses each step's contribution to efficiency and product quality.
43
What are the 3 VSM steps?
1) Assessment/Measurement (current state), 2) Analysis/root cause (plan), 3) Adjustment (future state)
44
What are the 4 basic software development activities?
1) Establishing requirements (WHAT to do), 2) Creating design (HOW to do it), 3) Implementing code (translating to source code), 4) Testing implementation (ensure it works)
45
What is DFM?
Design for Manufacturing. Designing products with manufacturing ease in mind. Goal: lower production cost without sacrificing quality. Consider product/process strategy, analyze manufacturing functions at design stage.
46
What is DFA?
Design for Assembly. Designing products for ease of assembly. Minimize part count, maximize ease of handling/insertion. Lower labor costs, reduced inventory/WIP.
47
What are the 3 DFA criteria questions?
1) Does the part move relative to others? 2) Must it be of different material? 3) Must it be separate for assembly/disassembly? If all NO, consider combining parts.
48
What is assembly efficiency formula?
Ema = (Nmin × ta) / tma. Where Nmin = theoretical minimum parts, ta = basic assembly time, tma = actual assembly time.
49
What is the DFM single-setup rule?
MINIMIZE THE NUMBER OF STAGES AND SETUPS THROUGH WHICH A PART OR ASSEMBLY MUST GO BEFORE IT BECOMES A PRODUCT. Reduces WIP, scrap, tooling costs.
50
What are the 5 dimensions of profitability in product development?
1) Product Quality (how well it satisfies needs), 2) Product Cost (spending/profit margin), 3) Development Time (responsiveness to market), 4) Development Cost (how much spent to develop), 5) Development Capability (team experience as future asset)
51
What is MUDA?
Japanese word for waste. Any activity, cost, or resource in organization that does not help produce or add value to external customer.
52
What is Partial Design?
Early-stage concept generation. Ensures compatibility with physics. Functionality under simple conditions. Design should respect physics - when design conflicts with physics, physics always wins.
53
What are the 2 types of innovation?
Incremental innovation = predictable, small improvements. Disruptive/Radical innovation = surprising, market-changing (long adoption times).
54
What are 2 weaknesses most relevant to product development?
1) Failures of cooperation (throw-it-over-the-wall style), 2) Lack of awareness that brilliant results are often answers to wrong question. Focus on preventing problems vs solving problems.
55
What is Cash Drain #1?
Pushing for technology there's no pull for (example: phone with built-in razor)
56
What is Cash Drain #2?
Disregarding customer's voice (listening to corporate specialists instead of customers)
57
What is Cash Drain #3?
Overreliance on initial 'eureka' concept
58
What is Cash Drain #4?
Pretend Designs: new and different but not better and not production-intent
59
What is Cash Drain #5?
Pampered Product: not seriously challenged, not tested in wide range of conditions
60
What is Cash Drain #6?
Hardware swamp: so many prototype iterations that all time spent debugging/maintaining hardware with no time to improve design
61
What is Cash Drain #7?
No thought into how it can be produced until final stages
62
What is Cash Drain #8?
We've always made it this way and it works (resistance to change)
63
What is Cash Drain #9?
Inspection: sorting good from bad after production is completed (reactive not proactive)
64
What is Cash Drain #10?
Give me my targets, let me do my thing (silo mentality, no collaboration)
65
What are the 4 components of Basic Concurrent Engineering (BCE) Improved Process?
1) Concurrent Process, 2) Focus on Quality Cost Delivery (QCD), 3) Emphasis on Customer Satisfaction, 4) Emphasis on Competitive Benchmarking (CBM)
66
What are the 3 components of BCE Closer Cooperation?
1) Integrated organization (multifunctional teams), 2) Employee involvement (participative management), 3) Strategic relations with suppliers (partnerships)
67
What are the 6 key aspects of FMEA?
1) Define scope and function, 2) Identify potential failures, 3) Prioritize potential failures, 4) Select and manage actions, 5) Observe and learn, 6) Document the process
68
What is mechanical failure?
Change in size/shape/material properties leading to loss of function. Failure mode is physical process leading to failure. Modes include: elastic deformation, yielding, rupture, fatigue, corrosion, wear, creep, buckling.
69
What is DFC?
Design for Cost. Early cost estimation is critical. Cost breakdown: material, labor, overhead, tooling. Rule of thumb: Material:Manufacturing:Selling = 1:3:9. 80% of cost comes from 20% of components.
70
What is DFV?
Design for Value. Value = Function worth ÷ Cost. Identify functions, life-cycle cost, worth to customer. Eliminate low-value features.
71
What is DFS?
Design for Sustainability. Consider environmental effects of materials. Design for separability, reuse, recycling. Life cycle assessment: manufacture → use → reuse → recycle → disposal.
72
What is modular product architecture?
Independent chunks, flexible, easier to manage. Advantages: product families, flexibility, easier upgrades, reduced risk, easier testing/maintenance.
73
What is integral product architecture?
Blended functions, harder to separate components.
74
Communication satellites: what do they do and why?
They receive uplink signal, amplify it, transmit downlink signal to Earth. Works because high altitude provides minimal signal blockage and avoids Earth-curvature line-of-sight issues.
75
How do railroad wheels work without differential?
Wheels are conical shape (not uniform circle). When going around curve, conical shape allows shift: small diameter moves to inside of curve, larger diameter touches other track. Since radius and velocity are proportional (a=v²/r), inner wheel travels slower than outer wheel.
76
Maglev train principle of operation?
Front of train: opposite charges → attraction. Back of train: same charges → repulsion. Combined electromagnetic forces create forward motion.
77
Ice resurfacer (Zamboni) 4-step operation?
1) Shaves ice to remove bumps, collects snow in tank, 2) Applies thin layer of warm water, 3) Spreads water with squeegee, 4) Creates smooth even surface after freezing.
78
What is TQD and its other names?
Total Quality Development. Also called Improved Total Development Process (ITDP) or World Class CE (W
79
of operation?
Front of train: opposite charges → attraction. Back of train: same charges → repulsion. Combined electromagnetic forces create forward motion.
80
What is TQD and its other names?
Total Quality Development. Also called Improved Total Development Process (ITDP) or World Class CE (WCCE). Combines engineering, management, teamwork. Goal: reduced development time/cost, higher quality, more variety.
81
What are TQD success factors?
Responsiveness to customer needs, robust concepts and functional quality, manufacturability and maintainability, economic precision, integration (Apple/Tesla examples), prevention of problems, teamwork, management, strategy.
82
What is at the core of all development work?
CONCEPT CREATION. Design should respect physics - when design conflicts with physics, physics always wins.
CONCURRENT
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