ISyE 315 Quiz 2 Review Packet Spring 2024

Quiz 2 Review Packet

** Review your Discussion 5-9 packets (Lectures 8-18 material) **
Exam covers Chapters 11, 12, 13, 14, and 16 as well as Homework 4, 5, and 6

Topics - not necessarily exhaustive

• Process layout vs. Product layout vs. Cellular layout
• Method for creating and evaluating layouts (Systematic Layout Planning)
Manufacturing ▪ Establishing and interpreting flow and non-flow rankings (& AEIOUX
Processes / Process scale) - like in the project
Layouts ▪ Creating relationship/block diagrams
▪ Calculating Z (distance x flow)

• Considerations/trends for job design

• Common uses for production standards (costing, scheduling, capacity planning,
performance assessment, comparing designs)
• Pros/Cons of each work measurement method. What needs to be considered in
each method. (time study, work sampling, MOST)
• When is each work measurement method most appropriate

Normal time = 𝑡̅*F*RF

Task Normal time = sum of element normal times
Standard time = NT(1+allowances) or NT/(1-allowances)
𝑁
1
𝑠= √ ∑(𝑥𝑖 − 𝑥̅ )2
𝑁−1
𝑖=1

*welcome to use calculator to simplify std. dev. calculations

Job Design & Work
𝑧 𝑠 2
Measurement
Sample size: Time study: 𝑛 = [( ) ( ̅)]
𝑝 𝑡
n=required sample size
z=confidence level (for 95% confidence, z=1.96)
p=desired precision (accuracy) of estimate
t=select (average observed) time for element*
s=sample standard deviation for element*
*Use element with greatest percent deviation from mean → s/t x 100%

𝑧 2
Sample size: Work sampling: 𝑛 = [( ) ∗ 𝑝(1 − 𝑝)]
𝑠
s = desired accuracy
p = percentage occurrence of activity
Z = corresponding z -score

For MOST: remember that you can't switch between types of sequences (gen.
move, control move, tool use), you must complete the whole sequence first. You
can have multiple sequences and types for a problem - they are additive overall.
ISyE 315 Quiz 2 Review Packet Spring 2024
• How to handle scrap rates and efficiency (or utilization) rates in capacity
planning for machine requirements.
• How to determine the number of work stations and fill the stations with work
elements according to longest processing time or most followers rules
Product Layouts & • Reasons and method for line balancing - why does it help you?
Line Balancing • Little’s Law* understand the relationships between throughput (time),
throughput rate (units/time) or cycle time (time/unit), and WIP (units)
Process Design and • Blocking (can add to throughput) and starving (does not add to throughput
Analysis
time). Understand how parallel activities contribute to throughput (make sure
you don't double account for simultaneous processes).
• Determining cycle time, throughput time, and efficiency
• Identifying the bottleneck

• Purpose and procedure

Factor Analysis • Common factors to include
• Briefly review lectures slides. Understand the concept and use.

Chapter 12: TQM and Six Sigma
Total Quality Management
Cost of Quality
Dimensions of Quality and the different
definitions of quality
Six Sigma
DMAIC Methodology
DPMO
Poka-Yoke (mistake proofing)- examples
Benchmarking
Continual Improvement
Chapter 14: Lean Supply Chains
Lean layouts
Lean production schedules
Lean supply chains
Pull vs Pull system (how can we move to a
pull or demand driven system)
JIT: Just in Time
7 classes of waste: TIMWOOD
Kaizen and 5S (examples)
Kanban use and equations (pull system)
Value Streaming benefits
Chapter 13: SPC and Process Capability
Common and Special Cause Variation
Variable and Attribute Charts
Difference between process control and process
capability?
Difference between specification (product) and
control limits (process)
Defect vs. defective
Cp and Cpk: What info do they provide you?
WECO Rules! - Is it in control?
Calculating control limits and zones
Graphing data and interpreting
Chapter 16: Global Sourcing and Procurement
Strategic Sourcing
Inventory turnover
Weeks or days of supply
Bullwhip effect
Functional Products
Innovative Products
Outsourcing
Total cost of ownership (general concepts)
Mass Customization

Reminder: You can bring one 3x5 inch note card (both sides may be used) and a calculator for the
quiz. Note that any note cards larger than 3x5 inches may be confiscated. If needed, reference
materials (e.g., MOST, Normal Probability Tables) will be provided.
ISyE 315 Quiz 2 Review Packet Spring 2024
Equations
X - R charts LCL X = X − A2 R
Monitoring Process Mean
UCLX = X + A2 R
Monitoring Process Standard Deviation
 0 Estimated by X and  0 estimated by
R LCLR = D3 R
d2 UCLR = D4 R
LCL X = X − E 2 Rm
X_Rm charts
Moving Range Chart UCLX = X + E 2 Rm
(Use when a single measurement is available LCLRm = D3 Rm
– no rational subgroups of size n)
UCLRm = D4 Rm
p-chart (average fraction defective) 𝑝̅ = total number of defective items / total number of
items sampled

𝑝̅ (1−𝑝̅ )
𝜎𝑝 = √ , 𝐿𝐶𝐿𝑝 = 𝑝̅ − 3 ∗ 𝜎𝑝 ,
𝑛
𝑈𝐶𝐿𝑝 = 𝑝̅ + 3 ∗ 𝜎𝑝
np-chart (number of defectives) d = np = # of defectives
Control limits: 𝑛𝑝̅ ± 3√𝑛𝑝̅ (1 − 𝑝̅ )
c-chart (average number of defects in a Control limits: c ±̅ 3√(c ̅ )
sample) *Typically used when defects are scattered through
continuous flow of material
u-chart (average number of defects per unit) u = c/n, where c = total defects per subgroup of “n” units
u ̅ = total defects in k subgroups / total number of items
in k subgroups
Control Limits: u ̅±3√(u /̅ n)
Cp (spread) Cp =capability = need of customer / variation in process
𝑈𝑆𝐿−𝐿𝑆𝐿
=
6∗σ
A capable process should be: (USL-LSL) > 6* σ
Cp should be ≥ 1.33
Cpk (centering) Cpk = min(ZU, ZL)
(𝑈𝑆𝐿 − 𝑋̿ )
𝑍𝑈 =
3 ∗ σ𝑋
( 𝑋̿ − 𝐿𝑆𝐿)
𝑍𝐿 =
3 ∗ σ𝑋
kanban 𝐷 × 𝐿(1 + 𝑆)
𝑘=
𝐶
L = processing time per container + wait time to
replenish
Inventory Turnovers 𝐶𝑜𝑠𝑡 𝑜𝑓 𝐺𝑜𝑜𝑑𝑠 𝑆𝑜𝑙𝑑
𝐴𝑣𝑒. 𝐴𝑔𝑔. 𝐼𝑛𝑣𝑒𝑛𝑡𝑜𝑟𝑦 𝑉𝑎𝑙𝑢𝑒
Weeks of Supply 𝐴𝑣𝑒.𝐴𝑔𝑔.𝐼𝑛𝑣𝑒𝑛𝑡𝑜𝑟𝑦 𝑉𝑎𝑙𝑢𝑒∗52
𝐶𝑜𝑠𝑡 𝑜𝑓 𝐺𝑜𝑜𝑑𝑠 𝑆𝑜𝑙𝑑
ISyE 315 Quiz 2 Review Packet Spring 2024
Process Analysis
1.) Identify bottleneck. The activity with the longest duration is the bottleneck, and the duration
for that activity is equivalent to the cycle time.
2.) Identify blocking and starving. Each activity that is not the bottleneck will either be blocked or
starved. Activities will be slowed to the pace of the bottleneck if they are blocked.
in general- (may need to draw out the case if an activity is surrounded by a bottleneck)
a. Blocking time occurs to the left of the bottleneck because those activities must wait for
the bottleneck activity to complete a part before it can pass its part on.
b. Starving time occurs to the right of the bottleneck because those activities must wait for
the bottleneck activity to complete a part before it can receive its next part.
3.) Calculate throughput time. Throughput time is the sum of processing time and blocking time.
Starving does not contribute to throughput time.
4.) Interpret: What is the efficiency of this process? How can it be improved?

A B C D E

hint: may need to draw out a "time table" for process 1 to see effect of bottlenecks

Cycle Time Starving Blocking Throughput

Process 1

Process 2

Process 3

In an 8-hour day, what is the output of process 1?

ISyE 315 Quiz 2 Review Packet Spring 2024
Statistical Process Control (SPC)

A plastics injection molding process produces bucket lids. We wish to establish statistical control of
the diameter of the caps when manufactured by this process using 𝑋̅ and R charts. 30 samples, each
sample of size 5, have been taken when we think the process is in control. The inside diameter
measurement from these samples are given below.
30 30 30

å xi = 2134.012 å Ri = 0.975 å S = 0.4350

i
1 1 1
The specification limits on this lid are 84.000  0.05 cm.

(a) What are the control limits for 𝑋̅ and R chart?

(b) What is the process standard deviation?
(c) Chart the UCL, LCL, center line, and zones A, B, and C
(d) How do you determine if process is in control?
ISyE 315 Quiz 2 Review Packet Spring 2024
SPC (Continued)

Consider the following data for an SPC p-chart (average fraction defective). Based on an analysis of
n=100, the established average fraction defective p-bar is 0.045. Placing the control limits at +/- 3σ,
answer the following questions.

p(%) Time (a) Calculate the UCL and the LCL.

0.04 7:00
0.08 7:30 (b) Plot the data and identify/plot the process average, the CLs,
0.09 8:00 and zones A, B, and C. (note: zones typically for Xbar
0.01 8:30 charts, but wanted to have extra practice here)
0.10 9:00
0.05 9:30 (c) Is this process in a state of statistical control? Explain.
0.06 10:00
0.03 10:30
0.02 11:00
0.07 11:30
ISyE 315 Quiz 2 Review Packet Spring 2024
Process Capability

The aerosol can production process yields cans with an average pressure of 61 psi and a standard
deviation of 2 psi. Design specifications call for an average of 60 psi with a tolerances of +/- 5 psi.
a. Sketch the normal curve, clearly indicate the mean, USL, and LSL
b. Calculate Cp and Cpk? What do they tell you
c. What is the probability of producing a defect?
ISyE 315 Quiz 2 Review Packet Spring 2024
Job Design and Work Measurement

Terry’s Tavern is a new bar that just opened on campus. They need to know how long it takes someone
to enter the bar in order to make sure it doesn’t take too long. The entering the bar process involves
waiting in line, ID check, and putting ID back in wallet. Allowances for this process are 10%. The time
study data collected is as follows (in minutes):

Work Element Observation Number

1 2 3 4 𝑡̅ F RF s s/ 𝑡̅

Waiting in line 5 13.7 1

ID check 5.5 6.4 14.1 14.8 0.9

Put ID back in
wallet 5.7 6.7 14.2 15.1 1.05

What is the standard time this process takes? If a precision of +/- 10% and a confidence level of 95%
is required how many additional observations are required?
ISyE 315 Quiz 2 Review Packet Spring 2024
Job Design and Work Measurement (Continued)

The following work samples were taken:

Activity # observations
Attending to patients 35
Moving between stations 10
Consulting with doctors 10
Taking a break or idiling 10
Doing paperwork 35
Administration wants to know how much time nurses are moving between stations. Determine how
many random observations must be made to produce an accuracy of +/- 5% and a confidence level of
95%.

M.O.S.T.

**When breaking down the job, be sure to use full sequences from the M.O.S.T. tables. You cannot
mix-and-match letters. Put a 0 as the letter index if it is in the sequence and doesn’t have an
application to the job.
o Sum of the indices * 10 = TMUs.
o TMUs * .036 = seconds
Example: Terry walks three steps to grab a ruler lying on the ground and returns to his work station
where he sets it down. With the ruler within reach, he pushes it 6 inches (15 cm) to measure two points
that are 8 inches apart. Then he puts down the ruler on his work bench. Without moving, he grasps a
wrench and fastens bolt with 3 wrist strokes and sets the wrench aside.
ISyE 315 Quiz 2 Review Packet Spring 2024

ABGABPA GENERAL MOVE

A B G P
INDEX ACTION BODY MOTION GAIN CONTROL PLACE INDEX
DISTANCE
0  2 IN HOLD 0
 5 CM TOSS
1 WITHIN REACH LIGHT OBJECT LAY ASIDE 1
LIGHT OBJECTS SIMO LOOSE FIT
3 1-2 STEPS BEND AND NON SIMO ADJUSTMENTS 3
ARISE 50% HEAVY OR BULKY LIGHT PRESSURE
OCC BLIND OR OBSTRUCTED DOUBLE
DISENGAGE
INTERLOCKED
COLLECT
6 3-4 STEPS BEND AND CARE OR PRECISION 6
ARISE HEAVY PRESSURE
BLIND OR OBSTRUCTED
INTERMEDIATE MOVES
10 5-7 STEPS SIT OR STAND 10
16 8-10 STEPS THROUGH 16
DOOR
CLIMB ON OR
OFF

ABGMXIA CONTROLLED MOVE SEQUENCE

M X I
INDEX MOVE CONTROLLED PROCESS TIME ALIGN INDEX
PUSH/PULL/PIVOT CRANK SECONDS MINUTES HOURS OBJECT
(REVS)
1  12 INCHES .5 .01 .0001 TO ONE 1
(30 CM) POINT
BUTTON/SWITCH/KNOB
3 > 12 INCHES (30 CM) 1 1.5 .02 .0004 TO TWO 3
RESISTANCE, SEAT OR POINTS  4
UNSEAT INCHES (10
CM)
HIGH CONTROL
2 STAGES  12 INCHES (30
CM)
6 2 STAGES > 12 INCHES (30 3 2.5 .04 .0007 TO TWO 6
CM) POINTS
> 4 INCHES (10
CM)
10 3-4 STAGES 6 4.5 .07 .0012 10

16 11 7.0 .10 .0019 PRECISION 16

ISyE 315 Quiz 2 Review Session Spring 2016

ABGABP ABPA TOOL USE SEQUENCE

FASTEN OR LOOSEN
INDEX INDEX
FINGER WRIST ACTION (Use P3) ARM ACTION POWER
ACTION TOOL
FINGERS HAND WRENCH WRENCH HAND RATCHET WRENCH WRENCH HAND POWER
SCREW- SCREW- ALLEN ALLEN HAMMER T- ALLEN ALLEN HAMMER WRENCH
DRIVER DRIVER KEY KEY WRENCH KEY KEY SCREW
RATCHET RATCHET RATCHET DIA.
T- INCHES
WRENCH (MM)
1 1 1 1
3 1 1 1 3 1 1 ¼” (M6) 3
6 3 3 2 3 6 2 1 3 1” (M24) 6
10 8 5 3 5 10 4 2 2 5 10
16 16 9 5 8 16 6 3 3 8 16
24 25 13 8 11 23 9 4 5 12 24
32 35 17 10 15 30 12 6 6 16 32
42 47 23 13 20 39 15 8 8 21 42
54 61 29 17 25 50 20 10 11 27 54

11