Question

1. Four most common layout formats (170, PPT 4-10) – describe the four most common layout formats. 2. workcenter (Job shop) Layout (170-174, PPT 11-20) – for a given workcenter layout, be able to assess the material handling cost/distance. 3. Assembly Line Layout (174-180, PPT 21-40) – be able to balance an assembly line: 1) draw a precedence diagram, 2) determine the workstation cycle time, 3) determine the theoretical minimum number of workstations, 4) using the longest task time rule to assign tasks to workstations, and 5) evaluate the efficiency. 4. Work Cell, Project, and other nonmanufacturing Layout (181-185) – illustrate how to develop a layout for work cell, project, and layouts in nonmanufacturing settings.

Chapter 12 – Six Sigma Quality 1. Defining Quality (299-303, PPT 4-16) – be able to define quality and TQM; understand the four categories of cost of quality (COQ). 2. Total Quality Management (PPT 17-36) – be able to describe each of the seven concepts for an effective TQM program. 3. Six Sigma (303-310, PPT 24-29) – understand the Six Sigma approach to improving quality and productivity. 4. Tools of TQM (PPT 37-49) – describe the seven tools for TQM – what they are and when to use them. 5. ISO (310-312, PPT 50-55) – describe the ISO international quality standards.

Answer 1

1a)

1. Product or Line Layout - If all the processing facilities and machines are systematized according to the flow of operations of the product, the layout is called product type of arrangement. In this type of layout, only a single type of product is produced in an operating area. This part must be standardized and manufactured in large quantities to support the product layout.

2. Process or Functional Layout - The process layout is especially useful where the low volume of production is required. If the parts are not standardized, the process layout is low beneficial, because it has producer process flexibility than other. In this type of layout, the machines and not ordered according to the flow of operations but are arranged according to the nature or character of the operations. This layout is generally suitable for non-repetitive jobs.

3. Fixed Position Layout -

This type of layout is the least relevant for today’s manufacturing industries. In this type of layout, the important element remains in a fixed location, other materials, parts, accessories, machinery, manpower and other supporting equipment’s are brought to this point.

The major part or body of the product remains in a fixed location because it is too difficult or too big and as such it is economical and accessible to bring the necessary instruments and types of equipment to work along with the manpower. This type of layout is used in the assembling of boilers, water-powered and steam turbines and ships, etc.

4. Combination type of Layout -

Nowadays in the pure state, any one form of layouts discussed above is rarely seen. Therefore, generally, the layouts used in productions are the trade-off of the above mentioned layouts. Each layout has got some advantages and limitations. Therefore, manufacturers would to like use any type of layout as such.

Flexibility is a very important factory, so the layout should be so which can be made according to the requirements of the business, without much investment. If the good points of all types of layouts are combined, a compromise solution can be achieved which will be more prudent and flexible.

2a) Quality can be defined as the conformance to requirements or the fir for use for some intended purpose.

Total Quality Management (TQM) is the constant process of reducing or excluding errors in manufacturing, smoothening supply chain management, improving the consumer experience, and ensuring that workers are up-to-speed with their training.

There are four categories of COQ: internal failure costs (costs correlated with defects found before the consumer receives the product or service), external failure costs (costs correlated with defects found after the consumer receives the part or service), appraisal costs (costs acquired to determine the extent of conformance to quality specifications) and prevention costs (costs incurred to prevent failure and appraisal costs to a least).

2b) 7 principles of TQM are:

2c)

Six Sigma (6?) is a set of methods and tools for process improvement. It was given by engineer Bill Smithwhile working with Motorola in 1986 and Jack Welch made it central to his company strategy at General Electric in 1995.

It seeks to enhance the quality of the output of a method by identifying and removing the causes of errors and minimizing variability in production and business processes. It uses a set of quality management systems, mainly empirical, statistical systems, and creates a special infrastructure of people within the institution who are experts in these methods. Each Six Sigma scheme carried out within an organization follows a defined string of steps and has specific value targets, for example: reduce process cycle time, decrease pollution, lessen costs, increase consumer satisfaction, and increase earnings.