Exam 6: Process Analysis and Redesign

Charting operations for process analysis and redesign should include all of the process transformations that affect customer satisfaction.

Benchmarked companies must always be in the same industry.

Process charts should explicitly reflect everything that the process contributes to

_____ remains a leader in time-based management.

Good process innovations can occur because of external forces that impose safety restrictions,pollution regulations,and other governmental controls for the first time.

_____ can set down goals for achieving zero machine stoppages,no equipment failures,and avoidance of total systems breakdowns.

Remedial maintenance is a complete and total plan to prevent failures of various kinds.

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 also considering a third policy of remedial maintenance,which is to replace tools only on an as-failed basis.Costs are $8 per tool plus $12 per tool for installation labor.What is the estimated annual total cost of this policy?

Orders that produce learning about a new process (routing,equipment,skills,and training) can help the company develop _____.

The old engineering truism that changeover times and costs must increase with the use of higher volume-efficient equipment is disappearing.

VA is readily identified by the persistent use of a set of questions but does not include addressing which alternative materials might be used.

Why are process managers also line managers?

Value analysis (VA) studies the use of alternative materials that could provide equal or better properties at equal or lower costs.

Bar codes and RFID are popular ways of identifying the location of materials.

PDM programs are most valuable when failure is very costly and/or process stoppage is life threatening.

The application of _____ concepts reduces the downtime of high-volume equipment by doing much of the setup while the machine is working on another order,or the new order.

_____ is defined as steps that need to be taken after a process has been completed in order to revise its output.This includes preparing equipment and assisting people with a new job.

Using process analysis to adapt one system to fit another is a way of achieving improvement through _____.

TPM addresses only the worst kind of failure,which is a failure that stops the process.

_____ is the start of the changeover cycle.