List two of the seven wastes eliminated by the new factory layout.

Outline why Petra Care used value stream mapping to improve the efficiency of assembling the wheelchairs.

Outline one reason, other than cost, why this factory did not adopt computer integrated manufacturing (CIM).

Maximising flow is one of the strategies used in lean production.

Explain how sorting and stabilising the tools as shown in Figure 3 contributes to maximising flow at Petra Care.

Motion / movement ✓

Transporting ✓

Waiting ✓

Defects ✓

Do not accept inventory, overproduction, or over processing.

Award [1] for listing each waste eliminated by the new factory layout up to [2 max].

Value stream mapping is used to analyse current (existing) processes ✓

to visually spot (identify) wastes (weaknesses, aspects that do not add value) / to suggest an improved factory layout / to speed up assembly / to understand the flow of materials / to analyse information flow throughout the complete manufacturing process ✓

Award [1] for identifying why Petra Care used value stream mapping to improve the efficiency of assembling the wheelchairs and [1] for a brief explanation.

This company only assembles standard wheelchairs ✓
and does not require changeover ✓

Small scale production ✓
which does not justify the change ✓

Petra wishes to keep its employees ✓
who would otherwise lose their jobs if they adopt CIM ✓

Award [1] for identifying why this factory did not adopt computer integrated manufacturing (CIM) and [1] for a brief explanation.

Stabilize / Setting in order means tools are arranged ✓

to make them easy to find and put away ✓

Sorting means unnecessary tools have been removed from the workplace ✓

leading to a more organized workplace ✓

thus, reducing waiting (time wasted looking for tools) / reducing motion / speeding up the process of assembling the wheelchairs ✓

Award [1] for identifying how sorting and stabilizing apply to the organization of the tools and [1] for each distinct explanation up to [4 max].

Even though this question directly asked candidates to list two of the seven wastes, very few answered this correctly.

The majority of candidates were able to score at least 1 mark.

Candidates were able to score at least 1 mark. Most correct responses focused on the social aspect and job losses.

Few candidates were able to score a full mark as many confused sorting with stabilizing. Candidates mainly earned marks for stating that tools would be easier to find therefore reducing time wasted looking for them.