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Semester I Examinations 2011/
Exam Code(s) 1APE1, 1APE2, 1EM
Module Code(s) IE Module(s) Lean Systems
Paper No. 1 Repeat Paper
External Examiner(s) Dr. Ralph Riedel Internal Examiner(s) Ms. Mary Dempsey Prof. Sean Leen
Instructions : Answer question 1 and one other question.
All questions will be marked equally.
Duration (^) 2 Hours
No. of Pages Cover + 3 pages College/Discipline Mechanical and Biomedical Engineering Course Co-ordinator(s) Mary Dempsey
Requirements : None
Q1. COMPULSORY
[Note: A list of all icons required to produce the current state map is provided on page 3]
It was an ordinary day in the life of a process engineer Paul White. Paul had a presentation deadline looming at 9.30am. He arrived at the office at 8.15am and as he put his hand in his pocket he realised that the office keys were in the glove compartment of his car he returned to his car in the car park at 8.30am. Paul eventually arrived back to his office at 9.00am. He took his laptop and walked 10 minutes to the conference room where he connected the laptop to the system taking 5 minutes set up time. Realising that he was in the wrong room Paul gathered up his laptop and scrambled to the correct venue location (approx 10 minutes). After another 5 minute set up time Paul was ready to make his presentation with no time to spare.
i) Produce a current state Value Stream map from this data, depicting both the material/human and information flows. Include a timeline at the bottom of your map, showing the total lead-time from arrival at the office to the start of the presentation
ii) Identify the value added time and the throughput time for this logistical process between the hours of 8.15 and 9.30 i.e. 1 hour 15 minutes.
iii) Suggest Lean improvements for this process. Identify and describe some of the improvement opportunities that can be applied to the current state processes. Describe your ambitions for a future value stream map. Furthermore draw a new value stream map
iv) Eliminating the queuing quickens the time it takes to flow through a system. What are the disadvantages of removing those parts?
Q2.
i) Describe each type of leadership style, giving examples to assist your explanation. ii) QFD matrix is an example of a LeanSixSigma tool. What are the steps to designing a QFD? iii) There are four specific types of quality costs. Define each type and also give an example of each kind of quality cost you have defined. iv) OEE is critical for Lean Systems success. What are the components of OEE and how do they relate to process effectiveness?
Current state Value Stream mapping icons:
FIFO
Supermarket
Signal Kanban
Withdrawal Kanban
Production Kanban Level Loading
Pull
Kanban arriving in batches
Kanban Path
Kanban Post
First-In First-Out Flow
Outside Sources
Inventory Triangle
Information Process Box
Data Box (^) Person / People
