30 Manufacturing Metrics
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MANUFACTURING METRICS MANUFACTURING OPERATIONS Processing and assembly operations Processing assembly Other factory operations Material handling and storage Inspection and testing Coordination and control
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Transcript of 30 Manufacturing Metrics
MANUFACTURING METRICS
MANUFACTURING OPERATIONS
Processing and assembly operations
Processing
assembly
Other factory operations
Material handling and storage
Inspection and testing
Coordination and control
PRODUCTION OPERATIONS
CONTINUOUS PRODUCTION
Continuous production occurs when the production equipment is used exclusively for the given
product, and the output of the product is uninterrupted.
BATCH PRODUCTION
Batch production occurs when the materials are processed in finite amounts or quantities.
The finite amount of quantity of material is called a batch
FIFO
PLANT LAYOUT
1. Fixed position layout
We can find an example in the development of a ship. As the image shows the ship is fixed.
Operators work in different activities such as welding, grinding, etc. In this type of distribution,
operators can rotate around the object that is being fabricated.
2. Process layout
In this type of distribution the plant is organized to perform a specific process in a certain section. In
the example, we have three different objects to be processed. The object A and B pass to the lathe
area, then to the milling area and finally they are stored. While the C object first passes to the late
area, then to the milling area and finally the weld area before being stored. Depending on the type of
work that you want to perform on the object, a specific machine in each section is assigned. On
several occasions you can have a machine that have to perform the same work in two different
objects.
3. Cellular layout
Certain groups of machines are assigned to do continuous processes. In this type of distribution the
plant is organized in order to do different types of processes in the same section. For example, the
painting process in a given section of a factory. First, there are some containers where different
products are stored, next the object passes to the drying oven, then to the spray booth and finally
the object is cleaned.
4. Product layout
The plant is organized depending on the product. For example in an assembly. The object to be
manufactured go through three different processes previously to be stored. First it passes to the
welding process, next to the paint process, then to the assembly line and finally it is stored.
METRICS (CHAPTER 3)
CYCLE TIME
CNC minimizes tool change time
Example:
Make a thread
….. Take part
Tool set
Start operation
Tool set
Start operation
….. Tool set
BATCH PRODUCTION https://www.youtube.com/watch?v=ixPhogfZTHU
MANUFACTURING LEAD TIME
MLT is the total time required to process a given part of product through the plant.
Including:
lost time due to delays
time spent in storage
reliability problems
categories of activities:
operation: in machine
nonoperation
handling
storage
inspection
Various Processes
…
…
When we include non-operating time, then for part j
PRODUCTION RATE
Average Production Time
Production Rate
Example:
Tb = 1030 [pc]
Exercises:
1. Job shop Q = 1
Sometimes we can find processes which need to be produced in series, otherwise we might
be wasting time.
2. Mass production Q2 = 1000
Some processes work with a huge amount of production, this allow us to have a better use of
the time.
PRODUCTION CAPACITY
Production capacity is defined as the maximum rate of output that a production facility is able to
produce under a given set of assumed operation conditions.
The production rate is measured in periods such as:
Week – Month – year
Work center: consist of one worker and a one machine.
PC = n.Sw.Hsh.Rp
n : number of work center
Sw : number ok shift per period (sh/wk)
Hsh: number of hour per shift (8 hr/shift)
Capacity increase
Short term
Increase Sw
Increase Hsh
Longer term
Increases work center
Increase production rate
Reduce the number of operation
Utilization
U = Q / PC
Availability
Availability is a common measure to reliability for equipment
A = (MTBF – MTTR)/ MTBF
WORK IN PROCESS
WIP is the quantity of parts of products currently located in the factory that either are being
processed or are between processing operations
WIP Is the inventory that is being transformed from raw material to finished product
