Injection Molding Process Quiz

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Questions and Answers

What is the yield percentage for the Injection molding process as indicated in the content?

96%

100%

99% (correct)

90%

How many wires are considered for the given project material?

4,000 wires (correct)

2,000 wires

3,000 wires

5,000 wires

What is the cycle time (C/T) for the Injection molding process?

30 sec

60 sec

18 sec (correct)

145 sec

What is the total number of units produced in the project as shown in the provided content?

9,568 units Signup and view all the answers

What is the clearance time mentioned for the project?

0 sec Signup and view all the answers

Which of the following represents the goal set for the project yield?

96% Signup and view all the answers

How many outer components are referenced in the material requirements?

1,406 Signup and view all the answers

What is the total lead time (LT) mentioned for the project?

41.4 days Signup and view all the answers

How many shifts are indicated for the Injection molding process?

3 Shifts Signup and view all the answers

How long does the Flow STAR process take according to the stated cycle time?

145 sec Signup and view all the answers

What is the relationship between containers and kanbans?

The number of containers equals the number of kanbans. Signup and view all the answers

What does a free transport card on the board allow?

To transport an empty container. Signup and view all the answers

Which statement best describes the function of a free production card?

It enables the production of items for an empty container. Signup and view all the answers

In a downstream work center scenario, what does the transport card represent?

The movement of a full container to the next stage. Signup and view all the answers

How does one-piece flow relate to JIT/kanban?

It focuses on producing one item at a time for immediate delivery. Signup and view all the answers

What does the term 'heijunka' refer to in the context of JIT/kanban?

A method for leveling product output over time. Signup and view all the answers

What is the primary purpose of using a kanban system?

To manage inventory efficiently and minimize waste. Signup and view all the answers

Which of the following best describes the empty container's role in this context?

It is a signal that more items need to be produced. Signup and view all the answers

What problem is caused by excessive machines and installations?

Obstruction of smooth product flow Signup and view all the answers

Which of the following is NOT one of the 5S steps?

Scheduling Signup and view all the answers

What issue may arise when tools are dirty and poorly grouped?

Difficulty in finding necessary tools Signup and view all the answers

What consequence might unneeded parts stored between workstations create?

Clutter and confusion Signup and view all the answers

Which of these statements about the necessity for 5S is true?

It aims to create a clean and organized work environment Signup and view all the answers

Which step in the 5S methodology involves maintaining standards?

Standardizing Signup and view all the answers

What is the aim of the 'Sustain' step in 5S?

To keep the work environment consistent over time Signup and view all the answers

Which step involves organizing tools and materials logically?

Setting in order Signup and view all the answers

What is the Takt Time mentioned in the content?

84 seconds Signup and view all the answers

Which principle does the term 'Waarde' relate to?

Value creation Signup and view all the answers

Which supplier is identified in the content?

Resin Supplier Signup and view all the answers

What improvement does the component scheduling aim to achieve?

Optimize material flow Signup and view all the answers

Which element is NOT mentioned as part of the production control?

Inventory management Signup and view all the answers

How does 'Takt Time' relate to production?

It indicates the rhythm of production. Signup and view all the answers

Which of the following best describes a goal of lean production?

Reduce turnaround time. Signup and view all the answers

What does the term 'issuing strategy' refer to in the context of production?

Scheduling component deliveries. Signup and view all the answers

Which aspect is crucial for maintaining efficient material flow?

Clear communication channels. Signup and view all the answers

In lean principles, the focus on the timing of actions is most closely related to which concept?

Takt time Signup and view all the answers

What is the fifth step of the 5S method?

Sustain Signup and view all the answers

Which of the following is NOT one of the 5 steps in the 5S method?

Stabilizing Signup and view all the answers

What is the main benefit of the 5S method for employees?

Greater engagement and ownership Signup and view all the answers

Which term refers to the step where a systematic approach is implemented across the organization in the 5S method?

Standardize Signup and view all the answers

In the context of the 5S method, what does 'Shine' primarily refer to?

Cleaning the work environment Signup and view all the answers

How can managers foster a culture of 5S among workers?

By conducting regular audits and showcasing progress Signup and view all the answers

Which characteristic is essential for the ‘Sustain’ step in the 5S method?

Autonomy of employees Signup and view all the answers

What is one approach to ensure compliance with the 5S practices?

Creating self-directed teams for continuous audits Signup and view all the answers

What is the yield percentage based on the data provided?

87% Signup and view all the answers

What is the cycle time (C/T) for the material identified as 'C/T = 55 sec'?

55 seconds Signup and view all the answers

How many balloons were produced as per the data?

14,088 Signup and view all the answers

Which of the following indicates the component with the highest output?

Balloons Signup and view all the answers

What is the target goal for yield percentage?

96% Signup and view all the answers

What does the acronym C/O stand for in this context?

Changeover Signup and view all the answers

How many units of tubing are scheduled for production?

80,000 Signup and view all the answers

What is the cycle time (C/T) of the component with the maximum C/T noted?

10 min Signup and view all the answers

Which area had a yield of 100%?

Tubing Signup and view all the answers

What is the withdrawal clearance time denoted as?

C/O = 10 min Signup and view all the answers

Which part had zero units produced?

HPC Signup and view all the answers

What is the significance of having 0 nonconformity material reports (NCMR) from the data provided?

Indicates excellent quality control Signup and view all the answers

Which statement best describes FIFO in this context?

First In, First Out strategy for inventory Signup and view all the answers

In total, how many inners were produced as indicated?

38,843 Signup and view all the answers

Study Notes

Lean Learning Academy Presentation Notes

The presentation is about Lean principles and methodology.

5 Lean Principles

Identify value
Map the value stream
Create flow
Create pull
Strive for perfection

Lean Thinking

Lean Thinking is a management philosophy for developing processes and systems to identify value for all stakeholders.
The focus is on eliminating waste and increasing customer satisfaction.

Muri, Mura, Muda

Muri (Overburden): Overloading, stress, and non-ergonomic design
Mura (Un-Evenness): Imbalances in processes with variability, peaks, idle time, and non-cyclical activities
Muda (Waste): Overproduction, waiting, transportation, processing, inventory, motion, and defects

Types of Waste (Muda) in Lean

Overproduction: Producing more than is needed.
Waiting: Unnecessary delays in the process.
Transportation: Unnecessary movement of materials.
Processing: Unnecessary steps in the process.
Inventory: Excess stock of materials.
Motion: Unnecessary movement of people or equipment.
Defects: Errors or mistakes in the process.

Key Points of 5S

The 5S method (Sort, Set in order, Shine, Standardise, Sustain) aims to improve workplace organization for efficiency and safety.

5S Method in detail

Sort: Removing unnecessary items from the workplace
Set in Order: Organising and arranging workplace in a standardised way
Shine: Cleaning and maintaining the workplace, keeping it tidy and organised
Standardise: Establishing standardised procedures for ongoing maintenance and improvements
Sustain: Implementing 5s as a daily routine. Maintaining the standards.

Current State/Future State of Value Stream Mapping in Detail

A visual tool representing the workflow of a product from raw material to finished product and customer.
Shows the flow of materials, information, and the value chain.
The current state map documents the existing processes.
The future state map illustrates the target state by highlighting potential process improvements, efficiency gains, and waste reduction.

Value Stream Manager Role

Overseeing the entire value stream, not just isolated departments
Leading the implementation of improvements
Maintaining a plan for future improvements

Additional Principles for Value Stream Improvement

Produce at a rate of takt time to meet customer demand
Create a continuous flow without any unnecessary delays, ensuring smooth movement of products
Implement super markets which operate as temporary buffers to assist maintaining a consistent flow
Focus the production towards the customer need to avoid creating excessive inventory
Balance the production volume of varied products
Reduce unnecessary rework and handling of goods in different directions
Use a pull system to start the production process only once a demand or need is confirmed

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Description

Test your knowledge on key metrics of the Injection Molding process, including yield percentage, cycle time, and total units produced. This quiz covers essential aspects of project material requirements and timelines. Perfect for engineering students and professionals looking to evaluate their understanding of this manufacturing technique.