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Lecture-02 Modeling

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21 views

Lecture-02 Modeling

Uploaded by

www.mo7amed.gameed
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Lecture #2

Performance measures of
manufacturing systems
1.4 Performance measures of manufacturing systems
1) Production Quantity and Product Variety
total quantity of all parts or products made in the factory

Where
Qj = annual quantity of style j.
P = total number of different part or product styles

The total number of product models is given by :

P1 refers to the number of distinct product lines produced by the factory


P2 refers to the number of models in a product line
Problem 1:
A manufacturing plant produces three product
lines in one of its plants: A, B, and C. Each product
line has multiple models: 3 models within product
line A, 5 models within B, and 7 within C. Average
annual production quantities of model A is 400
units, 800 units for model B, and 500 units for model
C.
Determine the number of
(a)different product models and
(b)total quantity of products produced annually in
this plant.
Solution:
P1 = 3 (A, B, C) product lines.
P21 = 3 models, P22 = 5 models; P23 = 7 models
Average annual production units:
Q1 = 400 units/yr, Q2 = 800 units/yr; Q3 = 500 units/yr.
a] the number of different product models:

b] total quantity of produced annually:


Product and Part Complexity
For an assembled product, one possible quantitative indicator of
product complexity is its number of components—the more parts,
the more complex the product is.
Complexity of an assembled product can be defined as the
number of distinct components;
Let, np = the number of parts per product.
For a manufactured component, a possible measure of part
complexity is the number of processing steps required to produce
it.
Processing complexity of each part can be defined as the number
of operations required to make it;
let
no = the number of operations or processing steps to make a part.
Product and Part Complexity
Assuming that the products are all assembled and that all component parts used
in these products are made in the plant (no purchased components), the total
number of parts manufactured by the plant per year is given by

where
npf = total number of parts made in the factory, pc/yr;
Qj = annual quantity of product style j, products/yr; and
npj = number of parts in product j, pc/product.
Finally, if all parts are manufactured in the plant, then the total number of
processing operations performed by the plant is given by

nof = total number of operation cycles performed in the factory, ops/yr; and

nojk = number of processing operations for each part k,


summed over the number of parts in product j, npj.
Product and Part Complexity
Average values of the four parameters P, Q, np, and no might be used to simplify and
better conceptualize the factory model.
The total number of product units produced by the factory is given by:

The average Q value is given by the following:

The total number of parts produced by the factory is given by:

where the average np value is given by the following:

The total number of manufacturing operations performed by the factory is given by

where the average no value is given by the following:


Example:
Suppose a company has designed a new product line and is planning to
build a new plant to manufacture this product line. The new line
consists of 100 different product types, and for each product type the
company wants to produce 10,000 units annually. The products average
1,000 components each, and the average number of processing steps
required for each component is 10. All parts will be made in the factory.
Each processing step takes an average of 1 min.
Determine:
A. how many products?
B. how many parts?
C. how many production operations will be required each year? and
D. how many workers will be needed in the plant, if each worker works
8 hrs./shift for 250 days/yr. (2,000 hrs./yr.)?
Solution:
(a) The total number of units to be produced by the factory annually is given
by
Q = PQ = 100 * 10,000 = 1,000,000 products
(b) The total number of parts produced annually is
npf = PQnp = 1,000,000 * 1,000 = 1,000,000,000 parts
(c) The number of distinct production operations is
nof = PQnpno = 1,000,000,000 * 10 = 10,000,000,000 operations
(d) First consider the total time TT to perform these operations. If each
operation takes 1 min (1/60 hr),
TT = 10,000,000,000 * 1/60 = 166,666,667 hr
If each worker works 2,000 hr/yr, then the total number of workers required is
Manufacturing lead time (MLT):
MLT is the total time required to process a given product through the plant.

In case of balanced operation times: TO1 = TO2 = …..= TOnm

For a job shop: batch size = 1 or Q=1

For mass production: Q is very large and dominates the other terms. the MLT simply
becomes the operation time for the machine after the setup has been completed and
production begins.

WS1 WS2 WS3


For flow-type mass production:

MLT = nm (transfer time tr+ longest To) tr tr


Production rate (throughput rate)
For the batch production:
the total batch time for the machine is the time to process one batch consisting
of Q work units.

or
q = scrap rate.

The average production time per unit of product for the given machine:

The average production rate for the machine:

RP = hourly production rate pc/hr


For job shop production: When Q=1

TP = Tsu + To
for quantity type mass production: Tb = To
Problem 5:
A certain part is routed through six machines in a batch production plant. The
setup and operation times for each machine are given in the following table:
Machine Setup time(h) Operation time (min)
1 4 5.0
2 2 3.5
3 8 10.0
4 3 1.9
5 3 4.1
6 4 2.5
The batch size is 100 and the average nonoperation time per machine is 12 hrs.
(a) Determine the manufacturing lead time.
(b) Determine the production rate for operation 3.
Solution:
Average Tsu = (4 + 2 + 8 + 3 + 3 + 4)/6 = 24/6 = 4.0 hrs
Average To = (5 + 3.5 + 10 + 1.9 + 4.1 + 2.5)/6
= 27/6 = 4.5 min.
(a)
MLT = 6(4.0 + 100(4.5/60) + 12) = 6(23.5) = 141 hr

(b) Rp for operation 3:


Tp = [8.0 + 100(10/60)]/100 = 24.67/100
= 0.2467 hr/pc
Rp = 1/ Tp = 4.05 pc/hr
Production capacity (PC):
It 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. Assumed operating conditions refer to number of shifts
per day (one, two, or three), number of days in the week (or
month) that the plant operates, employment levels.
PC = w Sw H RP
Where
PC = production capacity of the facility (output units/wk)
w = number of work centers producing in the facility (number of
machines)
Sw= number of shifts per period (shift/wk)
H= hrs./shift (hrs.), and
RP = hourly production rate of each work center (output units/hr)
Production capacity (PC):
If we include the possibility that each work unit is
routed through no operations, with each operation
requiring a new setup on either the same or a different
machine:
Then, the plant capacity:

Where
no= number of distinct operations through which work units are
routed.
Utilization and availability:
Utilization refers to the amount of output of a production
facility relative to its capacity

Where
U = utilization of the facility
Q = actual quantity produced by the facility during a given time
period (i.e. pc/wk)
PC = production capacity for the same period (pc/wk)
Utilization and availability:
Availability is a common measure of reliability for
equipment

Where
A = availability
MTBF = mean time between failures (hr)
MTTR = mean time to repair (hr)
Work In Process (WIP):
WIP is the quantity of parts or products currently located in the
factory that are either being processed or are between
processing operations.
WIP is inventory that is in the state of being transformed from raw
material to finished product.

Where
WIP = work in process in the facility, pc
U = utilization
PC = production capacity of the facility, pc/wk
MLT = manufacturing lead time, wk
Sw = number of shift per week, shift/wk
H = hours per shift, hr/shift.
Work In Process (WIP):
The WIP ratio:
Provides an indication of the amount of inventory in process
relative to the work actually being processed. It is the total
quantity of a given part (or assembly) in the plant or section of
the plant divided by the quantity of the same part that is being
processed (or assembled).

Where

W = number of available work centers in the plant


U = plant utilization
Q = average batch quantity
To, Tsu = operation time and setup time
Work In Process (WIP):
The ideal WIP ratio is 1:1, which implies that all parts
in the plant are being processed.
In a high volume flow line operation, the ratio close
to 1:1.
In a batch production shop, WIP is higher, perhaps
50:1 or higher.

The TIP ratio:


Measures the time the product spends in the plant relative to its
actual processing time.

The ideal TIP is 1:1.

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