Exam 6: Process Analysis and Redesign

Input is often raised by productivity improvement programs (PIPS) without lowering quality,and sometimes raising it.

Marketing power is decreased when production flexibility is enhanced by a one-time fixed cost increase in facility expenses.

Operations can be decomposed into detailed elements such as searching for a part,reaching for it,grasping,and turning it.

_____ is repair and replacement at regular,scheduled intervals.

Alternative process flow designs are _____ possible.

How can process charts be used to optimize layout?

Value analysis comparisons between present and proposed materials are facilitated by using _____ chart analysis.

What is time-based management (TBM) and how can it be used to benefit an organization?

There is an information flow that parallels and mimics the materials that are moving through the input-transformation-output process.

The _____ is defined as the end step before the next setup,make-ready cycle.

The _____ chart provides both visual and quantitative data that summarizes the pros and cons of making changes.

A cutting tool has a lifetime that is normally distributed with an average life of 400 hours and a standard deviation of 50 hours.Present policy is preventive maintenance which requires changing all cutting tools at the end of each month.Current operations are two shifts per day and 7 working hours per shift.At 20 days per month,each cutting tool is in use 280 hours per month.(All cutting tools that fail are simply shut down until the end of the month sweep).The variable costs of replacement under the current policy are $8 per tool plus installation labor of $6 per tool.There are 40 tools in use. -What is the estimated annual cost of replacements under the current policy?

Product _____ is a direct function of process flow design.

The use of back-up equipment and employing other redundant systems are methods that do not constitute preventive maintenance.

A cutting tool has a lifetime that is normally distributed with an average life of 400 hours and a standard deviation of 50 hours.Present policy is preventive maintenance which requires changing all cutting tools at the end of each month.Current operations are two shifts per day and 7 working hours per shift.At 20 days per month,each cutting tool is in use 280 hours per month.(All cutting tools that fail are simply shut down until the end of the month sweep).The variable costs of replacement under the current policy are $8 per tool plus installation labor of $6 per tool.There are 40 tools in use. -Management is considering a change in policy that would change cutting tools every two months instead.Cutting tools that fail are replaced immediately,but the replacement labor is $16 per tool because each replacement is a special order.At the sweep,all tools,even recent replacements,are replaced.What is the annual cost of this proposed policy?

The effect of putting priorities on customers' orders is _____ encountered in materials dealing with scheduling.

Starting from scratch (reengineering a process) generally does not delay new order processing.

It is generally less expensive to use corrective maintenance than preventive maintenance.

Process charts use _____ to represent inspections.

In process redesign the method of continuous incremental improvements,which the Japanese call _____,is applied to quality enhancement.