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Stone Haven PDF
Stone Haven PDF
STONEHAVEN
Cut insole
4* (4
(4.00
00 + 100*0.04)
100*0 04) = 32
minutes
Cut insole
4* (4
(4.00
00 + 100*0.04)
100*0 04) = 32
minutes
10 pair batch
Capacity, CT and MLT
CUTTING DEPARTMENT
Cut insole
4* (4
(4.00
00 + 10 * 0.04)
0 04) =
17.6 minutes
Little’s Law
Manufacturing Lead Time = Work in Process * Cycle Time
STITCHING DEPARTMENT
10 pair batch
10 pair batch
Capacity, CT and MLT
STITCHING DEPARTMENT
10 pair batch
10 pair batch
Cycle
y Time is one minute perp ppair, driven by
y the Bottleneck “Rough
g Sole”
The conveyor belt must be paced at one minute per operation.
First pair comes out at 5 minutes ( 1 min each for the 5 operations)
The second pair comes off the line at 6 minutes, the third at 7 mins (“cycle time”)
((n + 4) mins, where n = batch number)
Thus the
Th th MLT for
f the
th batch
b t h off 100 pairs
i isi 104 minutes
i t (100 + 4)
With one batch allowed at one time, the Capacity is 480 / 104=4.62 batches=462 shoes
LASTING DEPARTMENT
10 pair batch
Capacity CT and MLT
Capacity,
LASTING DEPARTMENT
10 pair batch
Cycle
y Time is one minute perp ppair, driven by
y the Bottleneck “Rough
g Sole”
The conveyor belt must be paced at one minute per operation.
First pair comes out at 5 minutes ( 1 min each for the 5 operations)
The second pair comes off the line at 6 minutes, the third at 7 mins (“cycle time”)
((n + 4) mins, where n = batch number)
Thus the
Th th MLT for
f the
th batch
b t h off 10 pairs
i isi 14 minutes
i t (10 + 4)
With one batch allowed at one time, the Capacity is 480 / 14=34.3 batches=343 shoes
LASTING DEPARTMENT
Since one batch is allowed at one time, there will be a time at the end of the batch when
the beginning of the operations in the conveyor are idle.
LASTING DEPARTMENT
Minute by Minute snapshot of the Shoe Assembly line from T=99 to 103
10
Staple Sole Seat Last Rough Sole Cement Inspect &
99 98 97 96
0 Sole Pack
The steamer
steamer’ss six hours does not enter into calculations
The case states it has ‘significant excess capacity’
THE ENTIRE FACTORY’S MLT
THE ENTIRE FACTORY’S MLT
Little’s Law
Manufacturing Lead Time = Work in Process * Cycle Time
THE ENTIRE FACTORY’S MLT
Each department
p cannot run at its own maximum speed
p
Every department must run on a 125 minute cycle
WIP bbefore
f and
d after
ft departments
d t t : Table
T bl 2 off Case,
C
WIP within department from Case facts, except for Steaming (not given)
In Cutting,
g we have significant
g excess capacity
p y when
Batches are set at 100 pairs.
g capacity
Thus, if we cut down on batch size, Cutting’s p y
Will reduce, but NOT the System’s Capacity
As we change batches
batches, MLT and Cycle time gets
affected
400
Cap
0
0 10 20 30 40 50 60 70 80 90
Batch Size
THE APPROPRIATE BATCH SIZE
As we change batches
batches, MLT and Cycle time gets
affected
9000
MLT
1000
0 10 20 30 40 50 60 70 80 90
Batch Size
THE APPROPRIATE BATCH SIZE
IInspectt &
Staple Sole
Pack
0.7 mins
0.3 mins
LINE BALANCING – WHY NOT?
24
22
20
18
16
Cycle Time (hrs)
14
12
High
10
Variability
8
6
Low
4 Variability
Capacity
2
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2
Release Rate (entities/hr)
LINE BALANCING – WHY NOT?
MLT
0 80 100
Utilization
TOOLS AND TECHNIQUES
T tools
Two t l which
hi h help
h l us “to
“t see””
“Learning to see” tools