Process Engineering & Optimization Flashcards

Which lean concept focuses on producing only what is needed, when it is needed, and in the amount needed?

Answer: Just-In-Time (JIT)

Just-In-Time (JIT) manufacturing eliminates overproduction waste by aligning production output with actual demand.

A control chart shows data points consistently drifting upward over 8 consecutive points. This pattern is called:

Answer: A run or trend signal

Eight consecutive points trending in one direction on a control chart signal a non-random (special cause) trend requiring investigation.

What manufacturing layout arranges equipment in a U-shape to facilitate single-piece flow and flexible staffing?

Answer: U-shaped (cellular) layout

A U-shaped cellular layout enables operators to handle multiple machines, reducing WIP and supporting single-piece flow.

In Six Sigma, what sigma level corresponds to approximately 3.4 defects per million opportunities (DPMO)?

Answer: 6 Sigma

Six Sigma quality level allows no more than 3.4 DPMO, accounting for a 1.5-sigma long-term process shift.

Which type of waste in the lean framework refers to unnecessary movement of materials between process steps?

Answer: Transportation waste

Transportation waste involves moving materials or products unnecessarily, adding time and cost without adding value.

A Pareto chart is used in process engineering primarily to:

Answer: Identify which defect categories account for the majority of problems

Pareto charts apply the 80/20 rule to prioritize the few defect types responsible for most quality problems.

Which process engineering tool is used to error-proof a process and prevent defects from occurring or passing to the next step?

Answer: Poka-Yoke

Poka-Yoke devices or methods are designed to make errors impossible or immediately detectable before they become defects.