Manufacturing Operations 2

Production Concepts And Mathematical Models

Sejumlah konsep produksi bersifat kuantitatif, atau
mereka memerlukan pendekatan kuantitatif untuk
mengukurnya
Model yang dikembangkan dalam bagian ini sangat
ideal dalam arti bahwa mereka mengabaikan
beberapa realita dan komplikasi yang hadir di pabrik
¤ model disini tidak termasuk tingkat cacat (scrap)
Production Concepts And Mathematical Models

Production rate, Rp
Production capacity, PC
Utilization, U
Availability, A
Manufacturing lead time, MLT
Work-in-progress, WIP
 Production Rate
The production rate for an individual processing or
assembly operation is usually expressed as an
hourly rate, that is parts or products per hour
Three types of production:
¤ Job shop production
¤ Batch production
¤ Mass production
Production Rate
Tc = the operation cycle time
¤ The time that one work unit spends being processed or assembled/the
time between when one work unit begins processing (or assembly)
and when the next unit begins)
¤ The time an individual part spends at the machine, but not all of this
time is productive
¤ In a typical processing operation, such as machining, Tc
consists of:
• Actual machining operation time
• Workpart handling time
• Tool handling time per workpiece
Time changing from one tool to the next, tool indexing time for indexable inserts or for
tools on a turret lathe or turret drill, tool repositioning for a next pass, and so on some
activities do not occur every cycle; they must be spread over the number of parts
between their occurences to obtain an average time per workpiece
Production Rate
Typical cycle time for a production operation
Tc = To + Th + Tth
Tc = operation cycle time (min/piece)
To= time of the actual processing or assembly operation
(min/piece)
Th= handling time (min/piece)
¤ e.g., loading and unloading the production machine
Tth= tool handling time (min/piece)
¤ e.g., time to change tools
Production Rate: Batch Production
The time to process one batch consisting of Q work units
is the sum of the setup time and processing time

Tb = Tsu + Q.Tc

Tb = batch processing time (min)

Tsu = setup time to prepare for the batch (min)
Q = batch size or batch quantity (pieces)
Tc = operation cycle time per work unit (min/piece)
 Production Rate: Batch Production
• We assume that one work unit is completed each cycle and so Tc also
has units of min/pieces
• If more than one part is produced each cycle, then the equation must
be adjusted accordingly
• Dividing batch time by batch quantity, we have the average production
time per work unit Tp for the given machine:

T
Tp = b
Q
Tp = average production time per work unit (min/piece)
Production Rate: Batch Production
The average production rate for the machine is simply
the reciprocal of production time
It is usually expressed as an hourly rate

R p = 60
Tp

Rp = hourly production rate (pieces/hour)

Tp = average production time per work unit (min/piece)
The constant 60 converts hours to minutes, and vise versa
Production Rate: Job Shop Production

When quantity Q =1, the production time per

work unit is the sum of setup and operation cycle
times

Tp = Tsu + Tc

When the quantity is greater than one, then this

reverts to the batch production case
Production Rate: Mass Production
For quantity type mass production, we can say that the
production rate equals the cycle rate of the machine
(reciprocal of operation time) after production is
underway and the effects of setup time become
insignificant
That is, as Q becomes very large (Tsu/ Q) → 0 and

R p → Rc = 60
Tc
Rc = operation cycle rate of the machine (pieces/hour)
Tc = operation cycle time (min/piece)
The constant 60 converts hours to minutes, and vise versa
 Production Rate: Flow line mass Production

The production rate approximates the cycle rate of the production

line, again neglecting setup time
The cycle time of a production line is the sum of the longest
processing (or assembly) time plus the time to transfer work units
between stations

Tc = Tr + maxTo
Tc = cycle time of the production line (min/cycle)
Tr = time to transfer work units between stations each cycle
(min/piece)
max To = operation time at the bottleneck station or the maximum of
the operation times for all stations on the line, (min/cycle)
 Production Capacity
• Production capacity is defined as the maximum rate of output that a
production facility (or production line, work center, or group of work
centers) is able to produce under a given set of assumed operating
conditions
• The production facility refers to a plant or factory, and so term plant
capacity is often used for this measure
• The assumed operating conditions refer to the number of shifts per day
(one, two, or three), number of days in the week (or month) that the
plant operates, employment levels, and so forth
 Production Capacity
• Quantitative measures of plant capacity can be developed based
on production rate models derived earlier
• The production capacity (PC) of a given facility under consideration
presents the measure of capacity as the number of units produced at
such period.
• The production facility consists of a number of machines or work
centers (n). The machine or work center capable of producing at a rate
(Rp). Provision for setup time is included in the production rate
• Every work center operates for a number of shifts at period (S) with
a number of hours per shift (H)
 Production Capacity
Plant capacity for facility in which parts are made in one
operation (no = 1):

PC = n.S.H.R p
PC = production capacity of the facility (pieces/week)
n = number of work centers producing in the facility
S = number of shifts per period (shifts/week)
H = number of hours per shift (hours/shift)
Rp = hourly production rate of each work center
(pieces/hour)
 Production Capacity
If we include the possibility that each work unit is routed
through no operations (no > 1), with each operation
requiring a new setup on either the same or a different
machine, than the plant capacity equation must be
amended as follows
n.S.H.R
PC = p

no
no= number of distinct operations through which work units
are routed
 Production Capacity
• Changes that can be made to increase or decrease plant capacity over the
short term
• ¤ Change the number of shifts per week
• ¤ Change the number of hours worked per shift
• Over the intermediate or longer term, the following changes can be
made to increase plant capacity
• ¤ Increase the number of work centers, n, in the shop by using the equipment that was
formerly not in use and hiring new workers
• ¤ Increase the production rate, Rp, by making improvement in methods or process
technology
• ¤ Reduce the number of operations no required per work unit by using combined
operations, simultaneous operations, or integrations of operations
Example (3)
The turret lathe section has six machines, all devoted to the
production of the same part. The section operates 10
shifts/week. The number of hours per shift averages 8.
Average production rate of each machines is 17 pieces/hour.
Determine the weekly production capacity of the turret lathe
section

PC = n.S.H.R p
= 610817 = 8,160 pieces/week
 Utilization
Utilization refers to the amount of output of a production
facility relative to its capacity

Q
U=
PC

U = utilization of the facility (%)

Q = actual quantity produced by the facility during a given
time period (pieces/week)
PC = production capacity from the same period
(pieces/week)
 Utilization
• Utilization can be accessed for an entire plant, a
single machine in the plant, or any productive
resource (i.e., labor)
• For convenience, it is often defined as the proportion
of time that the facility operating relative to the time
available under the definition of capacity
• Utilization is usually expressed as a percentage
Example (4)
A production machine operates 80 hours/week (two shift, 5
days) at full capacity. Its production rate is 20 pieces/hour.
during a certain week, the machine produced 1,000 parts and
was idle the remaining time.
¤ determine the production capacity of the machine.
¤ what was the utilization of the machine during the week under
consideration?
PC = n.S.H.R p
= 1108 20 = 1,600 pieces/week
Q
U =
PC
1,000
= = 0.625 = 62.5%
1,600
 Availability
• Availability is a common measure of reliability for equipment.
Availability presents the state of being available.
• The characteristic of resource that is usable or operable to perform its
designed function. It is especially appropriate for automated production
equipment
• Availability is typically expressed as a percentage. Availability refers to
ratio of total available time during a given interval to the length of
interval
• When a piece of equipment is brand new (and being debugged),
and later when it begins to age, its availability tends to be lower
MACHINE LIFE CYCLE
Produksi normal

Waktu
Product Lifecycle
 PLC dan MLC
Produksi & Penjualan

PLC

MLC

Waktu
 PLC dan MLC
JANGKA PANJANG
Produksi/
Penjualan

Waktu
 Availability
Availability is defined using two other reliability terms
¤ Mean time between failure (MTBF): indicates the average length of time
the piece of equipment runs between breakdowns
¤ Mean time to repair (MTTR): indicates the average time required to
service the equipment and put it back into operation when a breakdown
occurs

MTBF − MTTR
A=
MTBF
A = availability (%)
MTBF = mean time between failure (hours)
MTTR = mean time to repair (hours)
Availability - MTBF and MTTR Defined
 Example (5)
Consider previous Example 3. Suppose the same
data from that example were applicable, but that
the availability of the machines A = 90%, and the
utilization of the machines U = 80%. Given this
additional data, compute the expected plant
output.
PC = n.S.H.R p
= 610817 = 8,160 pieces/week
Q = PC.U.A
= 8,16080% 90% = 5,875 pieces
 Manufacturing Lead Time
Manufacturing lead time (MLT) is defined as the total time
required to process a given part or product through the plant
Production usually consists of a series of individual
processing and assembly operations
Between the operations are material handling, storage,
inspections, and other nonproductive activities
The activities of production:
¤ An operation: is performed on a work unit when it is in the production
machine
¤ The nonoperation elements include handling, temporary storage,
inspections, and other sources of delay when the work unit is not in
the machine
 Manufacturing Lead Time

Tc = the operation cycle time at a given machine or workstation

Tno = the nonoperation time associated with the same machine
no = the number of separate operations (machines) through
which the work unit must be routed to be completely
processed
Tsu = the setup time required to prepare each production machine
for particular product
 Manufacturing Lead Time
MLTj = manufacturing lead time for part or product j (min)
Tsuji = setup time for operation i of product j (min)
Qj = quantity of part or product j in the batch being processed
(pieces)
Tcji = operation cycle time for operation i of product j (min/piece)
Tnoji = nonoperation time associated with operation i (min)
i = the operation sequences in the processing; i = 1, 2, …, noj

MLT j =  (Tsuji + Q jTcji + Tnoji )

noj

i=1
Manufacturing Lead Time
Assume that all setup times, operation cycle
times, and nonoperation times are equal for the
noj machines
Suppose that the batch quantities of all parts or
products processed through the plant are equal
and that they are all processed through the
same number of machines, so that noj = no
MLT = no (Tsu + Q.Tc + Tno )
 Example (6)
A certain part is produced in a batch size of 100 units. The batch
must be routed through five operations to complete the
processing of the parts. Average setup time is 3 hr/operation, and
average operation time is 6 min (0.1 hr). Average nonoperation
time due to handling, delays, inspections, etc., is 7 hours for each
operation. Determine how many days it will take to complete the
batch, assuming the plant runs one 8-hr shift/day.
MLT = no .(Tsu + Q.Tc + Tno )
= 5 (3 +100 0.1+ 7 ) = 100 hours = 12.5 days
Manufacturing Lead Time

For a job shop in which the batch size is one

(Q = 1)

MLT = no (Tsu + Tc + Tno )

 Manufacturing Lead Time
For mass production, the term Q is very large and
dominates the other terms
In the case of quantity type mass production in which a
large number of units are made on a single machine (no =
1), the MLT simply becomes the operation cycle time for
the machine after
the setup has been completed and productions begins
 Manufacturing Lead Time

For flow line mass production, the entire

production line is set up in advance
The nonoperation time between processing steps is
simply the transfer time Tr to move the part or product
from one workstation to the next
The station with the longest operation time sets the
pace for all stations
 Manufacturing Lead Time
For flow line mass production
MLT = time between start and completion of a given work
unit on the line (min)
no = number of operations on the line
Tr = transfer time (min)
max To = operation time at the bottleneck station (min)
Tc = cycle time of the production line (min/piece)

MLT = no .(Tr + maxTo ) = no .Tc

Manufacturing Lead Time
Since the number of station is equal to the
number of operations (n = no)

MLT = n.(Tr + maxTo ) = n.Tc

Work-in-Process
Is the quantity of parts or products currently located
in the factory that are either being processed or are
between processing operations
Is inventory that is in the state of being
transformed from raw material to finished
product
Represents an investment by the firm, but one that
cannot be turned into revenue until all processing
has been completed
Ilustrasi Proses Produksi
t=0

3’ 5’ 3’
 Ilustrasi Proses Produksi

t=3

3
3’ 5’ 3’

Inventori WIP delay

 Ilustrasi Proses Produksi

t=5

3
3’ 5’ 3’
 Ilustrasi Proses Produksi

t=6

3
3’ 5’ 3’

Inventori WIP
 Ilustrasi Proses Produksi

t=8

8 3
3’ 5’ 3’

Inventori WIP
delay
 Ilustrasi Proses Produksi

t=9

8 3
3’ 5’ 3’

Inventori WIP
delay
 Ilustrasi Proses Produksi

t = 10

8 3
3’ 5’ 3’

Inventori WIP
 Ilustrasi Proses Produksi

t = 12

8 3
3’ 5’ 3’

Inventori WIP
 Ilustrasi Proses Produksi
t = 13
Bottleneck
Resource
13

8 3
3’ 5’ 3’

Inventori WIP
delay
3 ke 8 = 5 menit
8 ke 13 = 5 menit
Artinya setiap 5 menit pabrik menghasilkan 1 unit produk (sama dengan waktu siklus di mesin 2, terbesar)
Work-in-Process
WIP = work-in-process in the facility (pieces)
A = availability
U = utilization
PC = production capacity of the facility (pieces/week)
MLT = manufacturing lead time (weeks)
S = number of shifts per week (shifts/week)
H = hours per shift (hours/shift)

A.U.PC.MLT
WIP =
S.H
 Example (7)

A batch production plant processes all parts through 4 machines (1

machine = 1 operation). Twenty-five batches are produced every
week. Average operating time is 9 minutes. Average setup time is 6
hours. Average size of batch is 40 parts. And the average non-
operating time per batch is 8 hours / machine. There are 16 machines
in the plant. The plant performs an average of 80 hours per week.
The rate of material disposal (scrap) is negligible.
Availability is 90%. Determine the amount of Work-In- Process!
If it operates 1 shift/day and working hour for 1 shift are 8 hours
Example (7)
n = 16 machines
Qf = 25 batches = 1,000 pieces
no = 4 operations
Q = 40 pieces
Tsu = 6 hours
Tc = 9 min
Tno = 8 hours
S = 10 shifts/week
H = 8 hours/shift
A = 90%
Example (7)
Tb = Tsu + Q.T
= 6 + 40 0.15 = 12 hours
Tb
Tp =
Q
12
= = 0.3 hour = 18 min
40
60
Rp =
Tp
60
= = 3.33 pieces/hour
18
Example (7)
n.S.H.R p
PC =
no
16108 3.33
= = 1,066.67 pieces/week
4
Qf
U =
PC
1,000
= = 0.9375 = 93.75%
1,066.67
Example (7)

MLT = no .(Tsu + Q.Tc + Tno )

= 4 (6 + 40 0.15 + 8) = 80 hours

A.U.PC.MLT
WIP =
S.H
90%  93.75% 1,066.6780
= = 900 pieces
108
 Excercise

A batch production plant processes all parts through 8 machines (1

machine = 1 operation). 30 batches are produced every week. Average
operating time is 15 minutes. Average setup time is 4 hours. Average
size of batch is 20 parts. And the average non-operating time per
batch is 5 hours / machine. There are 20 machines in the plant. The
plant performs an average of 120 hours per week. The rate of
material disposal (scrap) is negligible.
Availability is 85%. Determine the amount of Work-In- Process!
If it operates 1 shift/day and working hour for 1 shift are 8 hours