Process Analysis & Efficiency
Scenario:
Tom is working 3 activities that take 20 min each, and Mary is working 1 activity for 20 min. How do we make this process more efficient? (Concept)
What is Line Balancing?
What happens to capacity when you add more workers?
What is Capacity * number of workers? or What is a directly proportional increase?
What unit(s) are activity times measures in?
What is time per unit?
------ is the shortest time that the project can be completed?
What is Critical Path?
Little Law's Formula is...?
What is (Average inventory = Average flow time * Average flow rate) ?
The Buffer Rule is:
What is start with a buffer end with a buffer and segment between each activity?
Given unlimited demand does adding workers increase or decrease the labor content?
What is it stays the same?
If batch size increases, what happens to capacity with a setup time? (conceptual)
What is Capacity increases?
What is the method to find ES and EF using the Critical Path Method? (conceptual)
What is forward Pass?
Capacity formula is ...?
What is (batch size)/ ((batch size * activity time ) + setup time) ?
** note if there are additional workers you must:
# of workers * capacity
What is the bottleneck for the Breakfast at Paramount?
What is 2 employees getting drinks and processing payments?
**note this is also a resource in parallel
Describe the relationship between activity duration and activity cost?
What is linear?
A milling machine requires four setups per production cycle. Each setup takes 25 minutes. The processing time is 0.6 minute per unit. What batch size (rounded to the nearest whole number) will achieve a capacity of 50 units per hour?
What is 167?
Batch size = (Capacity × Setup)/[1 – (Capacity × Processing time)]. Capacity = 50/60 = 0.8333 unit per min. Setup = 25 × 4 = 100 minutes. Processing time = 0.6 minute. Batch size = (0.8333 × 100)/[1 – (0.8333 × 0.6)] = 167.
*d
How much slack can any node on the critical path have?
what is 0?
Labor Utilization Formula is...?
What is (labor content) / (Cycle time * number of employees)
** note number of employees may be different than number of steps
Scenario:
t1: 15s t2: 15s t3: 10s t4: 35s t5:5s t6:40s
What is the capacity of the above process in hours?
90 units per hour
In a Project network the critical path could most recently compared to what earlier concept?
What is Bottleneck?
** Flow rate min( demand rate, maximum capacity)
** max capacity = bottleneck
A company uses a two-step process to make a part. The first step involves a drill press that requires a 60-minute setup time before the production of each batch can begin. After that, one unit can be drilled every 6 minutes. The second step involves attaching the drilled item to another device which takes 8 minutes per unit. Assuming demand is unlimited, what is the ideal batch size of the parts?
What is 30?
Demand is unlimited. Therefore the process is supply-constrained and the ideal batch size will balance the capacities of the resources (to minimize the inventory). Batch size = (Capacity × Setup)/[1 – (Capacity × Processing time)]. Target capacity = 1/8 = 0.125 unit per minute. Setup = 60 minutes. Processing time = 6 minutes. Batch size = (0.125 × 60)/[1 – (0.125 × 6)] = 30.
*d
A project has 2 paths
ABDF
ACEF
A = 5; B = 3; C= 8; D = 5; E = 2; F = 5
If Node B = 5, which activities would be critical?
What is All activities would be critical?
Target Batch Size Formula is...?
What is (target capacity * total set up time) / (1-(target capacity * activity time))?
**Note: DO NOT CALCULATE ALL STEPS TOGETHER
Draw a process map Scenerio:
General Motors has a new vehicle Model and it only takes 3 steps to make!!!
step 1: Constructing the frame (1 employee & 1 machine)
Step 2: Attaching wheels ( 4 employees & 4 machines )
Step 3: Wiring electric ( 1 employee )
TA check map
What is the difference between simultaneous resources and resources in parallel?
What is resources in parallel have the same output and the same resources duplicated, whereas simultaneous resources happen to be occurring at the same time?
C&A Pottery makes several lines of ceramic vases using a process that involves forming, drying, firing, and glazing. The 5 workers each take on average 60 minutes to form a vase. The vases will then be loaded into an oven to dry. The oven can hold up to 200 pieces and it takes 5 minutes to load each vase. Once all the vases are loaded into the oven, it takes 25 hours to dry each load. The dried vases are then placed in a kiln that holds up to 200 pieces. It takes 6 minutes to load each vase and the vases will be fired in the kiln for 72 hours. After firing, 4 workers each takes an average of 2 hours to glaze each vase. C&A can sell each vase that is made. What is the ideal batch size to minimize inventory while allowing the process to produce at maximum flow rate?
What is 180?
Capacity of the process = Min(5/1, 60/5, 60/6, 4/2) = 2. Batch size for the oven = (2 × 25)/[1 – (2 × 5/60)] = 60; Batch size for the kiln = (2 × 72)/[1 – (2 × 6/60)] = 180. The ideal batch size is 180 because that is the smallest batch size that allows both the oven and the kiln to operate at a rate that doesn’t constrain the flow.
*d
A project has 2 paths
ABDF
ACEF
A = 5; B = 3; C= 8; D = 5; E = 2; F = 5
Find the Critical Paths, and ES, EF, LS, LF, and Slack for each node
What is
A 0-5-0-5-0
B 5-8-7-10-2
C 5-13-5-13-0
D 8-13-10-15-2
E 13-15-13-15-0
F 15-20-15-20-0
ACEF = 20 ?
What is the relationship between Flow rate, Cycle Time, capacity, and activity time?
What is Flow rate min (process capacity, demand rate) and 1 / cycle time; 1/ activity time = capacity?
(edit)