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What is the primary purpose of value stream mapping?
Takt time is a fixed measurement that never changes.
False
What does the term 'takt' translate to in English?
cycle, beat, or pulse
The formula for Takt time is T = Ta / D, where Ta represents ____ and D represents ____.
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Match the following aspects of value stream mapping with their descriptions:
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Which of the following is NOT a mapping tip when creating a value stream map?
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Which of the following is referred to as 'Non-Utilized Talent'?
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Value stream mapping can only be conducted on production processes.
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What is the relationship between cycle time and takt time?
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Overproduction occurs when the amount of product manufactured meets customer demand.
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What type of waste is characterized by unnecessary movement of machinery, equipment, or people?
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When more steps are taken in production than necessary, this is known as __________.
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Which type of waste is most recognizable in manufacturing as it involves components or products that need reworking?
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Match the following types of waste with their descriptions:
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Skills waste only applies to the manufacturing industry.
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What is the term for waste caused by delays in the production process?
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What is one of the primary focuses of Lean Engineering?
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Value in Lean is defined as what the customer is willing to pay for.
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Name one of the steps involved in mapping the value stream.
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The principle of establishing a ______ system aims to limit inventory and work in process.
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Which of the following is considered a type of waste in Lean?
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Creating flow in Lean involves ensuring that processes run smoothly without interruptions.
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What is the ultimate goal of pursuing perfection in Lean principles?
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Match the types of waste with their descriptions:
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Study Notes
Why Value Stream Mapping
- Visualize the entire process
- Identify sources of waste
- Establish a common language for process descriptions
- Improves flow decision making
- Links lean concepts and techniques
- Basis for implementation plans
- Links information flow and material flow
- Qualitative tool describing actions
Starting Point
- Select a product family
- Assign one person to lead the mapping effort
- Begin at the door-to-door level
- Consider both material and information flows
Mapping Tips
- Physically walk the flow path
- Take a quick tour of the entire value stream
- Begin at the end of the value stream and walk back
- Record cycle times
- Map the entire value stream yourself
- Draw with pencil
Takt
- Takt time measures how much time is needed to produce one unit of goods to meet customer demand.
- Takt time helps companies balance minimal stock and avoid shortages.
- The word "Takt" comes from the German word "taktzeit", meaning cycle, beat or pulse.
- German aeroplane manufacturers first used the concept in the 1930s.
- Toyota adopted the concept in their production lines in the 1950s, calling it "ta kuto taimu."
Takt Formula
- Takt time = Net Available Time (Ta) / Demand (D)
- Total / Processing Cycle time is the time it takes to complete the process from start to finish.
- Cycle time must meet takt time or demand will not be met.
Inventory
- Inventory waste is storing value, like materials or finished products, that needs to be turned into something more valuable or sold to customers.
Motion
- Motion waste includes any unnecessary movement, stretching, bending, reaching, lifting and walking that doesn't add value.
Waiting
- Waiting waste is any inaction that increases costs.
- This includes time spent waiting for a product's transformation.
Overprocessing
- Overprocessing occurs when more steps, components or work is put into production than the customer needs.
Overproduction
- Overproduction waste occurs when more products or materials are produced than customers are willing to buy.
Defects
- Defects include missing details in assemblies, products requiring rework, and scrapped components and products.
Skills
- Skills waste also known as non-utilized talent.
- This waste occurs when management doesn't use all its workers to their fullest potential.
Lean Engineering and Value Stream
- Lean engineering focuses on understanding customer value and applying value drivers.
Value Drivers
- Price
- Quality
- Delivery
- Flexibility
- Service
Lean Principles
- Define Value: Identify customer value, focusing on what the customer is willing to pay for.
- Map the Value Stream: Identify and map all activities that contribute to customer value.
- Create Flow: Ensure a smooth flow without interruptions or delays after removing waste.
- Establish Pull: Limit inventory and work in process (WIP) items while ensuring materials and information are available for a smooth flow.
- Pursue Perfection: Continuous improvement and process refinement.
8 Types of Wastes - Muda
- Transportation: Unnecessary movement of products, equipment, inventory, tools and people.
- Inventory: Storing value that needs to be turned into something more valuable or sold.
- Motion: Unnecessary movement that doesn't add value.
- Waiting: Inaction that increases costs.
- Overprocessing: More steps or components than the customer needs.
- Overproduction: Producing more than what customers are willing to buy.
- Defects: Missing work, reworking, or scrapped components.
- Skills: Non-utilized talents of employees.
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Description
This quiz explores the principles and practical applications of value stream mapping and takt time in lean manufacturing. Participants will learn how to visualize processes, identify waste, and optimize flow decision-making. Understanding these concepts will enhance your ability to implement effective strategies in production environments.
