Beruflich Dokumente
Kultur Dokumente
and Metrics
Sections:
1. Mathematical Models of Production Performance
2. Manufacturing Costs
1
Why use metrics
2
Production Concepts and
Mathematical Models
3
Production Concepts and
Mathematical Models
Production capacity PC
Utilization U
Availability A
Manufacturing lead time MLT
Work-in-progress WIP
4
Operation Cycle Time
Tc = To + Th + Tth
where
Tc = cycle time (min/pc),
To = processing time for the operation (min/pc),
Th = handling time (min/pc) (e.g., loading and unloading the
production machine), and
Tth = tool handling time (min/pc) (e.g., time to change tools)
5
Production Rate (batch/job shop/flow)
Batch production:
Batch time Tb = Tsu + QTc
where
Tb= batch processing time (min)
Tsu= setup time to prepare for the batch (min)
Q= batch quantity (pc)
Tc = cycle time per work unit (min/cycle)
Mass production:
Rp Rc = 60/Tc since Tsu/Q 0 (Q is very large)
where
Rc = operation cycle rate of the machine (pc/hr)
Tc = operation cycle time (min/pc)
7
Production Rate (batch/job shop/flow)
Rc = 60/Tc
Rc = theoretical (ideal) production rate (cycles/hr)
8
Production Capacity
Operating conditions:
Number of shifts per day
Number of days per week
Employment levels
9
Production Capacity
Plant capacity for facility in which parts are made in one operation (no = 1):
PC = n Sw Hsh Rp
where
PC = weekly plant capacity (units/wk)
n = number of work centers working in parallel
Sw = number of shifts per week
Hsh = hr/shift
Rp = hourly production rate of each work center (output units/hr)
10
Production Capacity
Plant capacity for facility in which parts require multiple operations (no > 1):
nSw H sh R p
PCw =
no
where no = number of operations in the routing
11
Production Capacity
This capacity model assumes that all n machines are producing 100% of
the time and there are no bottleneck operations due to variations in
process routings to inhibit smooth flow of work through the plant.
There are some operations that are fully utilized while other operations
occasionally stand idle waiting for work.
12
Utilization and Availability
Q
Utilization: U =
PC
where Q = quantity actually produced, and PC = plant capacity
13
Utilization and Availability
MTBF MTTR
Availability: A =
MTBF
where MTBF = mean time between failures, and
MTTR = mean time to repair
“a common measure for reliability of equipment”
14
Availability -
MTBF and MTTR Defined
15
Manufacturing Lead Time
noj
16
Manufacturing Lead Time
17
Manufacturing Lead Time
Flow line
MLT = no (Tr + Max To) = no Tc
18
Work-In-Process
AU PC MLT Q MLT
WIP =
Sw H sh Sw H sh
where WIP = work-in-process, pc;
A = availability,
U = utilization,
PC = plant capacity, pc/wk;
MLT = manufacturing lead time, wk;
Sw = shifts per week,
Hsh = hours per shift, hr/shift
“quantity of parts or products currently located in the factory that are
either being processed or between processing operations”
“the inventory in the state of being transformed from raw material to
finished product” 19
Costs of Manufacturing Operations
20
Fixed and Variable Costs
21
Manufacturing Costs
22
Typical Manufacturing Costs
23
Overhead Rates
FOHC
Factory overhead rate: FOHR =
DLC
COHC
Corporate overhead rate: COHR =
DLC
where
FOHC=annual factory overhead costs ($/yr)
COHC= annual corporate overhead costs ($/yr)
DLC = annual direct labor costs ($/yr)
24
Example 3.5
Determine
a. The factory overhead rate for each plant
b. The corporate overhead rate
25
Cost of Equipment Usage
where
Co = hourly rate, $/hr;
CL = labor rate, $/hr;
FOHRL = labor factory overhead rate,
Cm = machine rate, $/hr;
FOHRm = machine factory overhead rate
26
Averaging Procedures for Production
Models
Q
j 1
j
Q
nQ
Q j batch quantity for part/product style j j 1,..., n
Q
27
Averaging Procedures for Production
Models
n
j 1
oj
no
nQ
noj number of operations in the process routing of
part/product style j
28
Averaging Procedures for Production
Models
T sujk
Tsuj k 1
noj
Tsujk setup time for operation k in the processing sequence
for part/product style j
29
Averaging Procedures for Production
Models
n T
j 1
oj suj
Tsu nQ
n j 1
oj
30
Averaging Procedures for Production
Models
T cjk
Tcj k 1
noj
Tcjk cycle time for operation k for item j
k 1, 2,..., n
oj
31
Averaging Procedures for Production
Models
n T
j 1
oj cj
Tc nQ
n
j 1
oj
32
Averaging Procedures for Production
Models
T nojk
Tnoj k 1
noj
Tnojk nonopertion time for operation k for item j
33
Averaging Procedures for Production
Models
n T
j 1
oj noj
Tno nQ
n j 1
oj
34