Injection Molding Process Quiz
58 Questions
4 Views

Choose a study mode

Play Quiz
Study Flashcards
Spaced Repetition
Chat to Lesson

Podcast

Play an AI-generated podcast conversation about this lesson

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?

<p>9,568 units (D)</p> Signup and view all the answers

What is the clearance time mentioned for the project?

<p>0 sec (A)</p> Signup and view all the answers

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

<p>96% (B)</p> Signup and view all the answers

How many outer components are referenced in the material requirements?

<p>1,406 (A)</p> Signup and view all the answers

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

<p>41.4 days (D)</p> Signup and view all the answers

How many shifts are indicated for the Injection molding process?

<p>3 Shifts (D)</p> Signup and view all the answers

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

<p>145 sec (D)</p> Signup and view all the answers

What is the relationship between containers and kanbans?

<p>The number of containers equals the number of kanbans. (C)</p> Signup and view all the answers

What does a free transport card on the board allow?

<p>To transport an empty container. (C)</p> Signup and view all the answers

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

<p>It enables the production of items for an empty container. (B)</p> Signup and view all the answers

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

<p>The movement of a full container to the next stage. (C)</p> Signup and view all the answers

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

<p>It focuses on producing one item at a time for immediate delivery. (A)</p> Signup and view all the answers

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

<p>A method for leveling product output over time. (B)</p> Signup and view all the answers

What is the primary purpose of using a kanban system?

<p>To manage inventory efficiently and minimize waste. (B)</p> Signup and view all the answers

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

<p>It is a signal that more items need to be produced. (C)</p> Signup and view all the answers

What problem is caused by excessive machines and installations?

<p>Obstruction of smooth product flow (A)</p> Signup and view all the answers

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

<p>Scheduling (D)</p> Signup and view all the answers

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

<p>Difficulty in finding necessary tools (D)</p> Signup and view all the answers

What consequence might unneeded parts stored between workstations create?

<p>Clutter and confusion (A)</p> Signup and view all the answers

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

<p>It aims to create a clean and organized work environment (C)</p> Signup and view all the answers

Which step in the 5S methodology involves maintaining standards?

<p>Standardizing (B)</p> Signup and view all the answers

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

<p>To keep the work environment consistent over time (C)</p> Signup and view all the answers

Which step involves organizing tools and materials logically?

<p>Setting in order (C)</p> Signup and view all the answers

What is the Takt Time mentioned in the content?

<p>84 seconds (C)</p> Signup and view all the answers

Which principle does the term 'Waarde' relate to?

<p>Value creation (D)</p> Signup and view all the answers

Which supplier is identified in the content?

<p>Resin Supplier (D)</p> Signup and view all the answers

What improvement does the component scheduling aim to achieve?

<p>Optimize material flow (A)</p> Signup and view all the answers

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

<p>Inventory management (A)</p> Signup and view all the answers

How does 'Takt Time' relate to production?

<p>It indicates the rhythm of production. (D)</p> Signup and view all the answers

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

<p>Reduce turnaround time. (D)</p> Signup and view all the answers

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

<p>Scheduling component deliveries. (A)</p> Signup and view all the answers

Which aspect is crucial for maintaining efficient material flow?

<p>Clear communication channels. (A)</p> Signup and view all the answers

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

<p>Takt time (A)</p> Signup and view all the answers

What is the fifth step of the 5S method?

<p>Sustain (D)</p> Signup and view all the answers

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

<p>Stabilizing (A)</p> Signup and view all the answers

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

<p>Greater engagement and ownership (C)</p> 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?

<p>Standardize (D)</p> Signup and view all the answers

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

<p>Cleaning the work environment (D)</p> Signup and view all the answers

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

<p>By conducting regular audits and showcasing progress (A)</p> Signup and view all the answers

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

<p>Autonomy of employees (B)</p> Signup and view all the answers

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

<p>Creating self-directed teams for continuous audits (B)</p> Signup and view all the answers

What is the yield percentage based on the data provided?

<p>87% (A)</p> Signup and view all the answers

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

<p>55 seconds (B)</p> Signup and view all the answers

How many balloons were produced as per the data?

<p>14,088 (D)</p> Signup and view all the answers

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

<p>Balloons (D)</p> Signup and view all the answers

What is the target goal for yield percentage?

<p>96% (B)</p> Signup and view all the answers

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

<p>Changeover (C)</p> Signup and view all the answers

How many units of tubing are scheduled for production?

<p>80,000 (A)</p> Signup and view all the answers

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

<p>10 min (A)</p> Signup and view all the answers

Which area had a yield of 100%?

<p>Tubing (A)</p> Signup and view all the answers

What is the withdrawal clearance time denoted as?

<p>C/O = 10 min (B)</p> Signup and view all the answers

Which part had zero units produced?

<p>HPC (A)</p> Signup and view all the answers

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

<p>Indicates excellent quality control (A)</p> Signup and view all the answers

Which statement best describes FIFO in this context?

<p>First In, First Out strategy for inventory (D)</p> Signup and view all the answers

In total, how many inners were produced as indicated?

<p>38,843 (D)</p> Signup and view all the answers

Flashcards

Takt Time

The amount of time needed to produce one unit of a product to meet customer demand. Measured in seconds.

Value

A lean principle focusing on delivering value to the customer by eliminating waste.

Material flow

A lean principle promoting continuous flow in production processes.

Inventory

A lean principle aimed at minimizing inventory throughout the production process.

Signup and view all the flashcards

Daily Schedule

A daily scheduling tool in lean manufacturing to allocate work tasks.

Signup and view all the flashcards

Production Control

A lean principle focusing on quality control throughout the entire production process.

Signup and view all the flashcards

Perfection

A lean principle emphasizing perfect execution and preventing errors to eliminate waste.

Signup and view all the flashcards

Teamwork

A lean principle promoting a collaborative approach to problem solving.

Signup and view all the flashcards

Improvements

A lean principle involving actively seeking and implementing improvements to the production process.

Signup and view all the flashcards

Waste

A lean principle of identifying and eliminating waste in all aspects of the production process.

Signup and view all the flashcards

Goal = 96%

A manufacturing process that aims to achieve a high yield of 96%, showcasing the importance of efficiency and productivity.

Signup and view all the flashcards

C/T

Refers to the time taken to complete a specific operation within the manufacturing process, often measured in seconds. Eg. 55 seconds.

Signup and view all the flashcards

Items Count ( x2)

Indicates the number of products processed through a particular stage within the manufacturing line, denoted by 'x' symbols. Eg. x2

Signup and view all the flashcards

Component

Represents an individual component or section within the manufacturing line that plays a crucial role in the overall production process. Eg. Plasma Treat.

Signup and view all the flashcards

Location

The location within the manufacturing line where specific actions take place. Eg. 'T/A MR Line #2'

Signup and view all the flashcards

Withdrawal

A key stage in the manufacturing process where components are removed from the production line. Eg. Withdrawal.

Signup and view all the flashcards

Area

The area within the manufacturing line where a certain task or stage takes place. Eg. 'Clearance Area'

Signup and view all the flashcards

Issuing Strategy

A strategy or plan for managing the flow of items within the manufacturing line, often based on a first-in, first-out (FIFO) principle.

Signup and view all the flashcards

C/O

The total time taken to complete an entire cycle within the process, typically measured in minutes. Eg. 10 minutes.

Signup and view all the flashcards

Yield

The percentage of successful products produced compared to the total number of products processed, representing the efficiency of the manufacturing process. Eg. 87%.

Signup and view all the flashcards

Materials

Refers to various tools or equipment used in the manufacturing process, highlighting the importance of materials in the production line. Eg. Balloons, Tubing.

Signup and view all the flashcards

Storage

A critical stage in the manufacturing process where materials are stored and managed, emphasizing inventory management and resource allocation.

Signup and view all the flashcards

Throughput

The volume of products processed through the manufacturing line within a specific timeframe, indicating the overall productivity. Eg. 100 units.

Signup and view all the flashcards

Plasma Treat

The stage in the manufacturing process where materials are treated with a plasma to enhance their properties, emphasizing the use of advanced technologies. Eg. Plasma Treat.

Signup and view all the flashcards

Production Rate

The rate at which a production line is able to produce units. It's calculated by dividing the number of units produced by the time it takes to produce them.

Signup and view all the flashcards

Cycle Time

The time it takes for one unit to move through the entire production process, from start to finish.

Signup and view all the flashcards

Supplier Pre-Inspection

An inspection conducted by the supplier before sending goods to the customer. It's designed to catch errors early and prevent defective products from reaching the customer.

Signup and view all the flashcards

Lean Manufacturing

A process that attempts to eliminate waste and improve efficiency at every stage of production. It focuses on identifying and eliminating non-value-adding activities.

Signup and view all the flashcards

Continuous Improvement

An essential component of lean manufacturing, it involves finding and implementing improvements to the production process. It focuses on continuously improving the process to minimize waste and maximize efficiency.

Signup and view all the flashcards

Flexibility

The ability of the production process to respond quickly to changes in demand. It's the ability of the system to adjust to fluctuations in customer needs.

Signup and view all the flashcards

Resilience

The ability of the production process to seamlessly handle any unexpected disturbances or problems. It's the ability of the system to prevent production stoppages and maintain stable operation.

Signup and view all the flashcards

Process Flow

A way of organizing the production process to ensure a smooth flow of materials and information. It's about creating a system that minimizes waste and ensures continuous operation.

Signup and view all the flashcards

What is the objective of 5S?

An organization method used in manufacturing and other industries to create a more efficient, clean, and organized work environment.

Signup and view all the flashcards

Describe the 5 steps of the 5S method.

It involves sorting, setting in order, shining, standardizing, and sustaining a workplace.

Signup and view all the flashcards

What is the objective of the 'Sort' step in 5S?

This step involves identifying unnecessary items and removing them from the workspace.

Signup and view all the flashcards

What is the objective of the 'Set in order' step in 5S?

This step aims to arrange remaining items in a logical and efficient manner.

Signup and view all the flashcards

What is the objective of the 'Shine' step in 5S?

This step involves cleaning the workspace and keeping it tidy.

Signup and view all the flashcards

What is the objective of the 'Standardize' step in 5S?

This step involves establishing and documenting standardized procedures for the first three steps.

Signup and view all the flashcards

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

This step involves maintaining the improvements achieved in the previous steps.

Signup and view all the flashcards

What are the benefits of implementing 5S?

It can improve productivity, reduce waste, enhance safety, and foster better teamwork.

Signup and view all the flashcards

Full container quantity

Each full container holds a specific quantity mentioned on the associated kanban card.

Signup and view all the flashcards

Free transport card

A free transport card on the board allows a vacant container to move to a different location.

Signup and view all the flashcards

Free production card

A free production card on the board allows workers to produce items for the next container.

Signup and view all the flashcards

Outgoing inventory point

The place where finished items are stored from the supplying work center.

Signup and view all the flashcards

Incoming inventory point

The place where items are stored before being processed by the receiving work center.

Signup and view all the flashcards

Product flow

Represents the movement of products between work centers, driven by pull principles.

Signup and view all the flashcards

JIT/Kanban system

The system uses kanban cards to manage production and material flow.

Signup and view all the flashcards

One downstream work center

Work center S requires only one supplying work center (work center R).

Signup and view all the flashcards

What is the 5S method?

This method focuses on tidiness, organization, cleaning, standardization, and maintaining those standards in a workplace.

Signup and view all the flashcards

What does 'Seiri' (Sort) mean in the 5S method?

The first step in the 5S method involves separating necessary and unnecessary items in the workplace. This includes discarding obsolete materials and storing needed tools effectively.

Signup and view all the flashcards

What does 'Seiton' (Set in order) mean in the 5S method?

The second step organizes remaining items by arranging them in a clear and logical order. This allows for easier access to tools and materials, promoting efficiency.

Signup and view all the flashcards

What does 'Seiso' (Shine) mean in the 5S method?

The third step involves cleaning the work area to eliminate dirt, debris, and any clutter. This ensures a safe and hygienic workplace with improved productivity.

Signup and view all the flashcards

What does 'Seiketsu' (Standardize) mean in the 5S method?

The fourth step involves standardizing the processes adopted for cleanliness and organization. Standardized procedures ensure consistency and prevent deviations, promoting a well-maintained workspace.

Signup and view all the flashcards

What does 'Shitsuke' (Sustain) mean in the 5S method?

The fifth and final step involves maintaining the previous four steps consistently. It requires continuous effort to sustain the organized and clean workspace and establish a culture of discipline in following the standards.

Signup and view all the flashcards

What are the benefits of implementing the 5S method?

The 5S method offers numerous benefits, including a safer work environment, improved efficiency, reduced waste, and a more enjoyable workplace.

Signup and view all the flashcards

What are some considerations for implementing the 5S method?

Implementing the 5S method requires planning, communication, worker involvement, and a commitment to change. It's important to create a supportive environment and motivate workers to embrace the new processes.

Signup and view all the flashcards

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

Studying That Suits You

Use AI to generate personalized quizzes and flashcards to suit your learning preferences.

Quiz Team

Related Documents

Wat is Lean? 2024 PDF

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.

More Like This

The Injection Molding Process Quiz
8 questions

The Injection Molding Process Quiz

SucceedingMountainPeak avatar
SucceedingMountainPeak
Injection Molding Quiz
5 questions

Injection Molding Quiz

SlickBlue avatar
SlickBlue
Coating Categories and Injection Molding Process
23 questions

Coating Categories and Injection Molding Process

SpeedyFreeVerse avatar
SpeedyFreeVerse
Processo di Iniezione e Stampaggio
49 questions

Processo di Iniezione e Stampaggio

WorthCamellia avatar
WorthCamellia
Use Quizgecko on...
Browser
Open
Browser
Browser