Podcast
Questions and Answers
What does 'N' stand for in the acronym DOWNTIME related to lean wastes?
What does 'N' stand for in the acronym DOWNTIME related to lean wastes?
Which of the following is a key characteristic of lean 'Production Precision'?
Which of the following is a key characteristic of lean 'Production Precision'?
Which waste is characterized by unnecessary movements of products and materials?
Which waste is characterized by unnecessary movements of products and materials?
What is the primary focus of lean thinking concerning inventory?
What is the primary focus of lean thinking concerning inventory?
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Which waste is often connected to excessive movement within a workspace?
Which waste is often connected to excessive movement within a workspace?
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What management approach is associated with high inventories and large production lots?
What management approach is associated with high inventories and large production lots?
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Which of the following best describes 'Waiting' as a lean waste?
Which of the following best describes 'Waiting' as a lean waste?
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How can a business best address the waste of 'Defects'?
How can a business best address the waste of 'Defects'?
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What is a key component of Overall Equipment Effectiveness (OEE)?
What is a key component of Overall Equipment Effectiveness (OEE)?
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In a lean manufacturing environment, which formula most accurately defines profit?
In a lean manufacturing environment, which formula most accurately defines profit?
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Which type of maintenance failure is categorized as 'self-induced'?
Which type of maintenance failure is categorized as 'self-induced'?
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What does the 'Pull' technique imply in shop floor supply management?
What does the 'Pull' technique imply in shop floor supply management?
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Which of the following practices is most beneficial in avoiding maintenance failures?
Which of the following practices is most beneficial in avoiding maintenance failures?
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Why is it important for teams participating in 5S audits to receive recognition?
Why is it important for teams participating in 5S audits to receive recognition?
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Which of the following statements is TRUE regarding Operations and Maintenance teams?
Which of the following statements is TRUE regarding Operations and Maintenance teams?
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What does the term 'standardize' imply in the 5S methodology?
What does the term 'standardize' imply in the 5S methodology?
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What is the formula for calculating Overall Equipment Effectiveness (OEE)?
What is the formula for calculating Overall Equipment Effectiveness (OEE)?
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If a machining center has an availability of 88.0%, a performance of 93.0%, and a quality rate of 95.0%, what is the OEE?
If a machining center has an availability of 88.0%, a performance of 93.0%, and a quality rate of 95.0%, what is the OEE?
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How is TEEP calculated using OEE?
How is TEEP calculated using OEE?
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What is the purpose of measuring TEEP as opposed to OEE?
What is the purpose of measuring TEEP as opposed to OEE?
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What is the result of the Utilization calculation if the machining center operates 20 hours a day for 300 days in a year?
What is the result of the Utilization calculation if the machining center operates 20 hours a day for 300 days in a year?
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What is the impact of unscheduled downtime on the Availability of equipment?
What is the impact of unscheduled downtime on the Availability of equipment?
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In the case study example, what was the scheduled maintenance time per shift for the equipment?
In the case study example, what was the scheduled maintenance time per shift for the equipment?
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If the designed production rate is 20 units and the actual production is 18 units, how would you calculate Asset Performance?
If the designed production rate is 20 units and the actual production is 18 units, how would you calculate Asset Performance?
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Study Notes
5S Methodology
- 5S is a methodology used to create a clean, organized, and efficient workplace
- Five Steps:
- Sort (Seiri)
- Set In Order (Seiton)
- Shine (Seiso)
- Standardize (Seiketsu)
- Sustain (Shitsuke)
Lean Manufacturing
- Pull System refers to a production system where products are made only when needed
- Push System refers to a system where products are made based on anticipations, leading to potential excess production
- Inventory is a major waste in Lean Manufacturing
- Production precision implies small lots, low inventories, and reduced waste
- Production approximation implies large lots, high inventories, and potential waste
7 Wastes of Lean
- The 7 wastes are: Overproduction, inventory, waiting, transportation, motion, defects and over-processing.
- These wastes can lead to reduced operational efficiency and increased costs
8 Wastes
- The 8 Wastes can be remembered using the acronym "DOWNTIME"
- The 8 wastes are: Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, and Extra-processing.
OEE (Overall Equipment Effectiveness)
- Measurement of effective use of production equipment
- Formula: Availability * Performance * Quality
- A world-class facility should aim for a utilization rate above 98%
- Key Components:
- Availability: The percentage of time equipment is available for production, calculated by dividing uptime by the sum of uptime and downtime
- Performance: Measures how efficiently equipment operates, calculated by dividing actual production rate by the designed (best) production rate
- Quality: Measures the percentage of good units produced from total units produced
TEEP (Total Equipment Effectiveness Performance)
- Measure of effectiveness based on 24 hours per day, 365 days per year operation
- Formula: Utilization * Availability * Performance * Quality
- Utilization is calculated by dividing the total time the equipment is operating by the total time available
Downtime Types
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Idle Time: Includes situations where the equipment is not in use due to factors like no demand, no feedstock, or not scheduled for production
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Scheduled Downtime: Refers to planned downtime for maintenance, repairs, and other scheduled events
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Unscheduled Downtime: Includes unplanned downtime due to unexpected repairs, failures, or external interruptions.
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Case Study 1
- Equipment availability is calculated by subtracting the total downtime from the total scheduled time and dividing by the total scheduled time.
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Description
Test your knowledge on Lean Manufacturing principles, including the 5S methodology and the various types of waste in production. This quiz covers essential concepts such as sorting, organizing, and sustaining efficiency in the workplace. Challenge yourself to recognize the differences between push and pull systems and the impacts of waste on operational efficiency.
