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    [Session 2] EN-B2.3-MEO-EXP5- Load Capacity exercices.pptx

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    Filda NZUZI-NGOMA

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    [Session 2] EN-B2.3-MEO-EXP5- Load Capacity exercices.pptx

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    Filda NZUZI-NGOMA
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    1 views17 pages

    [Session 2] EN-B2.3-MEO-EXP5- Load Capacity exercices.pptx

    Uploaded by

    Filda NZUZI-NGOMA

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    Industrialization 2

    EXP5 - MEO
    Load Capacity

    Session 2
    Loads and Capacity

    A work center is a basic operational unit that the company has decided to manage. It can
    include several physical units (machines) and / or several operators. It can also be an entire
    workshop.

    Each workload station will be characterized by its working capacity and its hourly cost. These
    two pieces of information will be determined based on the number of operators, the
    number of machines, the opening time of the station and the efficiency of the station.

    Robot A Welding station

    Capacity for this week : …….. Capacity for this week : ……..
    Hourly cost : ………. Hourly cost : ……….

    2
    Capacity examples

    3
    Capacity

    Design capacity = theoretical opening time / maximum output possible

    Effective capacity = Maximum output possible with consideration to situations like


    stops, breakdowns, preventive maintenance.

    Utilization rate (%) = Actual output / Maximum output


    possible

    *The theoritical opening time does not take into account any stop;
    ** The utilization rate of a work center is calculated from history.
    For any work center, the capacity is usually expressed in time

    4
    5
    6
    7
    One hour production
    is 200*0.75 = 150 units

    8
    9
    10
    Loads and Capacity
    Load :

    It is the quantity of work assigned to the process. This is usually expressed by "time".

    More load than the capacity of process is called overload while less load is called underload.

    Load = sum of times


    needed to produce

    Available
    Capacity
    Output
    flow

    11
    Reminder: routing sheets

    Work
    center

    Ex : Theoritical cycle time : for operation 20 :


    set up time = 0,5 / unit time = 0,1
    Operation
    => For 20 units, time = 0,5 + 20 x 0,1 = 2,5 h

    0,1

    Theoretical cycle time


    0,05
    0,05
    0,02
    0,1
    0,25 for 20 units with
    0,03
    Unit time
    Set up
    time
    0,5
    operation #20 ?

    the load is 2,5 h


    12
    Processes Lead Times
    Setup time:
    It means the status of preparing for making each machine available.
    It is required regardless of the work order quantity.

    Real operating time:


    It means the status of performing the work (bending, cutting, machining…) on each unit of the
    work order.
    This time depends on the quantity to produce.

    Post-processing time:
    It means the status of performing a post-process (e.g. removal or cleaning). It can be considered
    as a setup time for the next work.

    13
    Example
    Workcenter «injection» Work needed:
    • 3 injection molding machines, • 500 units to produce
    • running in 2 shifts (2 * 8h), • Set up time = 1h
    • With an efficiency of 80 % • Unit time = 0,05h
    • and an hourly cost of 28 €

    what is the capacity and the load ?

    Capacity = 0,8 x 3 x 2 x 8h = 38,4 h / day


    Load = 1 + 0,05 x 500 = 26h

    The work center is underload, we have enough capacity to produce the 500 units asked.

    14
    EXERCICES

    a plant is working with 2 teams / day, 8H/day, 5 days / week, 50 weeks/ year to produce their 3
    main products : A, B, C on only one machine,

    Calculate the capacity of the plant ?


    Calculate the load requested ?
    Is the plant overloaded or underloaded?
    What can be done?

    15
    EXERCICES
    a plant is working with 2 teams / day, 8H/day, 5 days / week, 50 weeks/ year to produce their 3
    main products : A, B, C on only one machine,

    Capacity : 2*8*5*50 = 4000 hours


    Load : 80 000*0.05 + 80000/240*0.5 + 60 000*0.1 + 60 000/180*2.2 + 120000*0.02 +
    120000/360*3.8 = 14 567 h

    Overloaded full
    solution increase capacity working with a third team, 7 days per weeks, → 8400 , not enough
    Buy new machines : 14567/4000 = 3,67. → Buy 3 new machines
    Mixt of the two previous solutions : cost analysis. 16
    Gantt and dates

    Earliest start day : Latest start day :


    the day when the operation can start at the It is a day when the operation order set
    earliest timing with the materials, facilities, according to the manufacturing order's
    and workers prepared delivery date is started at the latest timing. If
    it is started later than this day, the delivery will
    be delayed.

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