3. Analyze the way chili is made and served at Wendy's. Then, draw a process chart for the steps required to make and serve it. Draw a process flow layout chart for the Wendy's restaurant being studied.
There are many processes with which most people have some experience, such as changing a tire (a service) or baking a cake (a product). These are presented here along with some other processes that can be charted.
5. Analyze the service process of making travel arrangements. Then draw a process chart for a travel agent setting up the itineraries and reservations for a business trip to be taken by two company executives who are traveling by air from Chicago to Los Angeles. Draw a process flow layout chart for the agent and the agency. Compare this to booking on the Internet.
12. Research how to service copy machines. Create a process chart for providing this service on a business-like basis. What work configuration do you recommend?
The Preventive Maintenance Strategy Problem
In the subway system of Metropolis, there are 100,000 light bulbs that are at risk for failure with rates described as follows. The complete preventive maintenance policy is to replace all of the bulbs at once, four times per year. These light bulbs are long-life light bulbs, which cost more than regular ones.
Each of these bulbs has an expected average life of 3,000 hours and cost $7.00. The setup cost for each subway station is $5,000 and there are 50 stations.
In the subway, each light bulb remains lit, day and night, all year long, which is a total of 8,760 hours. Burned out and broken bulbs are only replaced during the TPM sweep. This could mean that station platform light is not always sufficient. At an extra cost, remedial replacement could be used. The total sweep would still take place, replacing all light bulbs, whether or not they were newly replaced.
17. For this problem, ignore remedial replacement and its extra cost.
Is a total replacement sweep four times per year likely to be sufficient? Note: The distribution is such that many light bulbs burn out long before the expected lifetime is reached, and many last considerably longer than 3,000 hours.
What is the total cost for following this TPM policy?
The Remedial and Predictive Maintenance Strategy Problem
The alternative strategy (using the information in Problem 17) is to replace each bulb as it burns out. Replacement costs $5 per light bulb in addition to the $7 purchase cost per bulb. As noted in the previous problem, the bulbs have an expected lifetime of 3,000 hours. Each light bulb in the subway remains lit, day and night, all year long, a total of 8,760 hours. The expected number of times each bulb will burn out per year is 2.9. For ease of calculation, round this off to 3 times per year that each light bulb must be changed.
19. How does the service (setup and changeover) procedure used for racing cars differ from that of regular auto servicing? Is there anything that can be learned from the difference? What does this query have to do with SMED?