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Process Analysis
Process Analysis
Process Analysis
What is a process?
A process is a series of independent tasks that
transforms an input into output material of
higher value for the organization
Examples:
Process Analysis
Lets look at the black box in more detail
Why do we need to analyze the process?
- To identify inefficient tasks
- To spot possible effectiveness improvement tasks
- To understand where value can be added
Task 2
FGI
Demand
Task 1
Task 2
Some examples
What are the tradeoffs?
Task 1
Task 2
Task 3
1
Throughput rate =
Cycle Time
Cycle Time =
Production Time:
25min/unit
What is a bottleneck?
Bottleneck is the
process stage with the
smallest throughput rate
(longest cycle time)
3 units/hr
5 units/hr
2 units/hr
Capacity of a process
The capacity of the process is:
3 units/hr
5 units/hr
2 units/hr
WIP
Throughput time =
Throughput rate
(Littles Law)
machining
assembly
machining
pack and
ship
machining
pack and
ship
Process Data:
machining: Set up 80 min. 4 min per unit processing.
Batch size 200. Identical lines.
assembly: Manual by two workers (no set up). Each
hammer requires 40 min processing. 34 workers available.
pack and ship: 30 min set up, 2 min per unit processing.
Lot sizes of 100.
Step 1: Machining
Look at one line. 200 units require:
80 + 200 4 = 880 minutes/200 units
The throughput rate is:
200 / 880 = 0.227 units/minute
= 13.63 units/hour
But we have two identical lines, so for the machining step
capacity is 2 13.63 = 27.26 units/hour.
Step 2: Assembly
1 unit requires 40 min processing time, so the
throughput rate is:
1 unit / 40 min = 0.025 units/min
= 1.5 units/hr
34 workers available, but 2 workers are required for
each unit, so assembly capacity is:
Similar to machining:
30 + 100 2 = 230 min/100 units
Pack & ship capacity is:
100 / 230 = 0.43 units/min
= 26.09 units /hr
Capacity (units/hr)
Machining
27.26
Assembly
25.50
26.09
Assembly is the
bottleneck!
Some vocabulary
Buffering: Keep some inventory between stages
0
1/2
0/2
2/2
1
1
More Examples..
Lets study this make-to-stock system.
CT = 3s
CT = 1s
Task 1
Task 2
FGI
More Examples..
CT = 3s
CT = 1s
Task 1
Task 2
FGI
More Examples..
Lets study this make-to-stock system:
CT = 1s
CT = 3s
Task 1
Task 2
FGI
More Examples..
CT = 1s
CT = 3s
Task 1
Task 2
FGI
More Examples..
Lets study this make-to-stock assembly system:
CT = 3s
CT = 3s
Task 1
Task 2
CT = 4s
Task 3
Note: No buffer space between stations
Is any task starved or blocked?
What is the capacity of the process?
CT = 2s
Task 4
FGI
More Examples..
CT = 3s
CT = 3s
Task 1
Task 2
CT = 4s
CT = 2s
Task 4
FGI
Task 3
Tasks 1 and 2 are blocked by Task 3 for 1 second per product.
Task 4 is starved for 2 seconds per product.
The capacity of the process is 15 units/hour (limited by Task 3).