IE 33: Systems Introduction and Quality Transformation
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Questions and Answers

What responsibilities does a Middle-Line Manager have?

Supervises 1st line managers, acts as a direct link between 1st line managers and top managers, handles more people than 1st line managers.

What is the main role of a 1st Line Manager?

To guide and direct the workers they supervise, view and improve S&P in their unit, and coordinate with other units in the organization.

Workers are staff or operating persons who supervise ______.

no one

What kind of problem should a Well-Defined Problem be?

<p>Quantified</p> Signup and view all the answers

Top Management approves company-wide changes based on S&P improvements, is this statement true?

<p>True</p> Signup and view all the answers

What is a system?

<p>A set of interrelated parts that work together toward a common goal.</p> Signup and view all the answers

What are examples of information outputs?

<p>Data for managers</p> Signup and view all the answers

All systems are completely isolated from their environment. (True/False)

<p>False</p> Signup and view all the answers

Schematic models can be represented by diagrams or charts, and mathematical models use ______ to represent relationships or functions.

<p>mathematical notation</p> Signup and view all the answers

Match the following categories of systems with their descriptions:

<p>Natural = Came into being through natural processes and exhibit high order and equilibrium. Human-Made = Intervened by human beings through components, attributes, or relationships. Human-Modified = A natural system integrated with a human-made system as a subsystem.</p> Signup and view all the answers

What is the purpose of a Business Model Canvas?

<p>To describe any business model using 9 blocks and to show how a system operates.</p> Signup and view all the answers

What is the main purpose of a Pareto Chart?

<p>To determine the top causes of a problem and prioritize solving them for the greatest improvement.</p> Signup and view all the answers

Which categories are used in the 5-Whys analysis to explore root causes?

<p>6Ms (Mother earth, machine, methods, material, management, man)</p> Signup and view all the answers

Lean Production sets emphasis on reducing error rates and maximizing productivity in product processes.

<p>True</p> Signup and view all the answers

What is the term for the group that a business is providing value for?

<p>Customer Segment</p> Signup and view all the answers

A Sub-Process can be further broken down into _________.

<p>Activities</p> Signup and view all the answers

Match the following process categories with their descriptions:

<p>Management Processes = Govern the operation of a system Operational Processes = Constitute the core business and create the primary value stream Supporting Processes = Support the core processes</p> Signup and view all the answers

What are immediate considerations focused on?

<p>Accomplishing tasks efficiently</p> Signup and view all the answers

Closed systems significantly interact with their environment.

<p>False</p> Signup and view all the answers

____ workers typically perform manual labor and earn an hourly wage.

<p>Blue</p> Signup and view all the answers

Match the type of effort involved in Systems and Procedures with the description:

<p>Designing S&amp;P for new work processes = Procedures planning Preparing written work procedures/instructions = Documentation of current processes Preparing, issuing, and maintaining S&amp;P manuals = Continuous maintenance work Reviewing, analyzing, and improving S&amp;P = Improvement through mechanization/automation</p> Signup and view all the answers

What does FIFO stand for?

<p>First In, First Out</p> Signup and view all the answers

What is represented by the supermarket icon?

<p>Small customer stock point</p> Signup and view all the answers

Cycle Time is the time it takes to complete a task.

<p>True</p> Signup and view all the answers

What is the formula for calculating Non-Value Added Time?

<p>(Inventory)(Takt Time)</p> Signup and view all the answers

Match the following:

<p>Push = Pushing of materials from one process to the next process Pull = Physical removal of material from the supermarket Kaizen Burst = Highlighting improvement needs and planning kaizen workshops Safety Stock = Temporary storage of stock against sudden fluctuations</p> Signup and view all the answers

What is the measure of system reliability known as?

<p>Uptime</p> Signup and view all the answers

What is Takt Time derived from?

<p>German word meaning pulse</p> Signup and view all the answers

The Kanban system is used as a way to manage high inventory levels.

<p>False</p> Signup and view all the answers

The _________ is the operation with the longest cycle time and determines total system output.

<p>Bottleneck Process</p> Signup and view all the answers

Match the following terms with their meanings:

<p>One Piece Flow = Production only when needed Batch Production = Producing in large quantities at once SMED = Single-minute exchange of dies Value Stream Mapping = Identifying and eliminating waste in processes</p> Signup and view all the answers

What is the purpose of the 'Seiri (Sort)' step in the manual creation process?

<p>Remove the unnecessary and keep only what is used</p> Signup and view all the answers

What is the main goal of writing the manual?

<p>Effective communication</p> Signup and view all the answers

What is the purpose of the 'Numbering System' in form control?

<p>identify the form and provide a ready index</p> Signup and view all the answers

Check boxes on forms help minimize the need for fill-ins and save time. Is this statement true?

<p>True</p> Signup and view all the answers

Where should instructions for filling in a form be placed for easy readability?

<p>At the top</p> Signup and view all the answers

Where should distribution and filing information be placed on a form?

<p>At the bottom</p> Signup and view all the answers

Which design style should be used for constant data on forms?

<p>Box design</p> Signup and view all the answers

What is the purpose of a flowchart?

<p>To graphically describe an existing or proposed process.</p> Signup and view all the answers

Which symbol in a flowchart represents the start or end of a process?

<p>Terminator</p> Signup and view all the answers

What creates blocks making it difficult for the eye to recognize the shape of the word?

<p>All caps</p> Signup and view all the answers

Flowcharts are primarily used to show a high-level overview of major system components or key process participants.

<p>True</p> Signup and view all the answers

Off white background is faster to read compared to bright white on black text.

<p>False</p> Signup and view all the answers

Avoid italics for long text blocks because it is difficult to read on screen or on paper form, instead use ______.

<p>regular font</p> Signup and view all the answers

Value Stream Mapping (VSM) is used for high production, low variety products with few components, subassemblies, and dedicated __________.

<p>equipment</p> Signup and view all the answers

Match the process measurement tool with its description:

<p>5S = Involves organizing, cleaning, developing, and sustaining workspace Kaizen Bursts = Quick improvement approach focusing on lasting change Benchmarking = Comparing processes with other organizations to identify gaps Voice of Customer = Gathering customer feedback data</p> Signup and view all the answers

Study Notes

Systems Introduction

  • A system is a set of interrelated parts that work together toward a common goal, with functional relationships between parts.
  • Important to define system boundaries and scope.
  • No system is completely isolated from its environment.

Types of Systems

  • Information System: provides information to people in an organization, e.g., CRS.
  • Service/Production System: transforms input to output, e.g., converting raw materials to finished goods.

Business Model Canvas

  • Descriptive tool that helps tell a story about how a business operates.
  • Composed of 9 blocks: Value Proposition, Customer Relationships, Distribution Channels, Customer Segment, Revenue Stream, Key Resources, Key Activities, Key Partners, and Cost Structure.

Systems and Subsystems

  • A system is part of a larger system (suprasystem) and may contain smaller systems (subsystems).
  • Example: A dam is a human-made system integrated into a natural system (river).

Classifications of Systems

  • Natural Systems: came into being by natural processes, e.g., food chains, water supply.
  • Human-Made Systems: created by human beings, e.g., rollercoasters.
  • Human-Modified Systems: natural systems integrated with human-made systems, e.g., dams.

Business Model Canvas Components

  • Value Proposition: what problem does your product solve and how does it meet customer needs?
  • Customer Relationships: how do you keep and grow your audience?
  • Distribution Channels: how do you inform and relay your products to your audience?
  • Customer Segment: what group are you providing value for?

Systems and Procedures

  • Analysis of corporate policies, procedures, forms, and equipment to simplify and standardize operations.
  • Procedure: a prescribed way of undertaking a process.
  • Work Instruction: a step-by-step guide on how to do a specific task.
  • Systems and Procedures are value-adding if the goal is achieved.

Types of Effort in Systems and Procedures

  • Designing new work processes and procedures.
  • Preparing written work procedures and instructions for existing processes.
  • Preparing, issuing, and maintaining Systems and Procedures manuals.

Considerations for Systems and Procedures

  • Before-The-Fact Considerations: planning, policy-making, and scheduling.
  • Immediate Considerations: accomplishing tasks, evaluating results, and considering continuation.
  • After-The-Fact Considerations: evaluating, reviewing, and improving Systems and Procedures.### Systems and Procedures
  • Importance of establishing and operating S&P controls: monitor and adjust processes to achieve desired output
  • Creating awareness for continuous improvement: sell the project initially and maintain interest through deeds
  • Increasing competence of managers: trainings and programs to improve S&P; most desirable objective
  • Responsibility Hierarchy:
    • Top Management: recognize value of well-organized effort, approve company-wide changes, and initiate S&P programs
    • Middle-Line Manager: supervise 1st line managers, handle more people, and coordinate laterally with other units
    • 1st Line Manager: guide and direct workers, improve S&P, and coordinate with other units
    • Workers: use procedural instructions, develop and use own S&P, and continuously improve systems

Systems Study Approach

  • Thinking: define the problem; a problem well-defined is half-solved
  • Gathering Data: methods include systems interview, physical examination of paper, emails, and fax transmissions
  • Analyzing Data: use statistical methods to identify trends and patterns
  • Developing and Evaluating Solutions: list and compare costs and benefits of options
  • Implementing and Preserving Solutions: write solutions into a manual, and involve the whole organization

Problem-Solving Tools

  • The 4-Whys: iterative interrogative technique to explore cause-and-effect relationships
  • Pareto Chart: bar graph to identify top causes of a problem and prioritize solutions
  • Ishikawa/Fishbone Diagram: visualize relationships between factors and categorize problems into management, social, and technological factors

Business Processes

  • Craft Production (1856): highly skilled workers, flexible tools, and customized products
  • Mass Production (1900s): narrowly skilled professionals, unskilled workers, and standardized products
  • Lean Production (1960s-1980s): perfection, zero defects, and variety of products
  • Business Process: set of activities that add value to inputs, producing outputs valuable to customers
  • Types of Processes:
    • Management Processes: govern the operation of a system
    • Operational Processes: constitute the core business and create primary value streams
    • Supporting Processes: support the core processes

SIPOC and Value Stream Mapping

  • SIPOC: high-level process mapping tool to give an overview of a process' inputs and outputs
  • Value Stream Mapping: visual tool to document all activities required to take a product or service from raw material to customer
  • Value Stream: all steps, value-adding or non-value-adding, required to take a product or service from raw material to customer### Value Stream Mapping (Current State)
  • Depicts the major elements and their interactions
  • Not useful during improvement due to lack of details

Process Box

  • Symbol represents the number of workers assigned to the process
  • Useful for a process of limited scope

Data Box

  • Specifies key parameters such as total cycle time, defects, changeover time, and uptime
  • Useful for understanding the process and identifying areas for improvement

SIRPORC

  • Stands for Suppliers, Inputs, Process, Outputs, Receivers, and Customers
  • Important concept in understanding value stream mapping

Inventory and Production Control

  • Supermarket: a small inventory point where customers come to pick up what they need
  • Pull System: physical removal of material from the supermarket
  • FIFO (First-In-First-Out): limits input and output
  • Shipment: movement of raw materials from suppliers to receiving docks and finished goods to customers
  • External Shipment: represented by an appropriate transportation vehicle
  • Production Control: also known as Central Production Scheduling Department

Information Flow

  • Electronic: exchange of information through fax, email, phone, or internet
  • Manual: exchange of information through memos, reports, and conversations
  • Withdrawal Kanban: specifies the kind and quality of product to be withdrawn from the preceding process

Timeline and Non-Value Added Time

  • Timeline: used to calculate lead time and total cycle time
  • Non-Value Added Time: = (Inventory)(Task Time) / Inventory
  • Cycle Time: time it takes to complete a task
  • Lead Time: time between displacement of customer order to delivery and receipt of the item

Step-by-Step Guide to Drawing a Value Stream Map

  1. Draw customer, supplier, and production control icons
  2. Enter customer requirements per month and day
  3. Enter available working hours
  4. Draw outbound and inbound shipping icons and frequencies
  5. Add process boxes in sequence
  6. Add communication arrows and note the methods of information exchange
  7. Add data boxes below
  8. Obtain process attributes and add to data boxes
  9. Add operator symbols and numbers
  10. Add inventory locations and levels in days of demand
  11. Add push, pull, and FIFO icons
  12. Add other useful information
  13. Calculate production lead time, value-added time, and process cycle efficiency

Other Concepts

  • Takt Time: the rate at which you need to complete the production process to meet customer demand
  • Uptime: measure of system reliability
  • Changeover Time: time it takes to switch from one product run to another
  • Process Cycle Efficiency (PCE): percentage of value-added time
  • Potential Workcells and Balance Workload: eliminate unnecessary tasks, combine tasks, and simplify the way we work
  • Operational Takt Time: = (Efficiency Factor)(Takt Time)
  • Number of Operators per Workstation: = Total Cycle Time / Operational Takt Time
  • Balanced Cycle Times: ensure smooth flow even with small inventory, thus short lead times

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Description

This quiz covers the basics of systems introduction, defining problems, and quality transformation to meet consumer demands. It assesses knowledge of outputs producing data and business processes.

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