11 Factory_Physics (1) - Factory Physics Definition The...

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Factory Physics Factory Physics
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Definition Definition The term factory physics denotes those manufacturing relationships that can be described mathematically, much as the term physics refer to physical relationships that can be framed in mathematical terms.
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Other Definitions Other Definitions Workstation : Collection of one or more machines or workers performing identical functions. Raw Material : parts purchased from outside. Components : individual pieces that are assembled into more complex products. Subassemblies : assembly of several components. End items : a part that is directly sold to the customer.
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Other Definitions Other Definitions Bill of Materials : list of parts that go into a product. Consumables : items used in production but are not part of a product. Routing: description of the sequence of workstations passed through by a part. Orders : request from a customer for a particular part number. Purchase order : a collection of one or more orders.
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Other Definitions Other Definitions Jobs : a set of physical materials that traverse routings together with the logical information. Throughput (TH ): the average output of a production process. Capacity of a station : upper limit in its throughput. Crib inventory : intermediate inventory location usually at the end of a routing. Finished goods inventory : place where the end items are held prior to shipping.
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Other Definitions Other Definitions Work in process (WIP) : the inventory between the start and the end points of a production routing. All the products between, but not including the stock points. Cycle time (CT): average time from release of a job at the beginning of a routing to until it reaches an inventory point at the end of the routing. I.e., the time the part spends as WIP. It is more difficult to define this for the entire product.
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Other Definitions Other Definitions Lead time: time allotted for production of a part on the routing. Service level: P{cycle time <= lead time) Fill rate : fraction of orders that are filled from stock. Bottleneck rate (r b ) = rate of the process center with the least long term capacity.
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Other Definitions Other Definitions Raw process time (T 0 ) = sum of the long-term average process times of each workstation in the line. Congestion coefficient ( ): a dimensionless coefficient that measures congestion in the line . Critical WIP level W 0 = minimum WIP level which yields output rate of r b . W 0 = r b * T 0
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Factory #1 Factory #1 Consider a production line composed of four machines. Identical jobs go through machines 1-4 repetitively. After each machine processes a job it becomes immediately available at the next station for processing. The line runs 24 hours a day with breaks and lunches covered by spare operators. For the sake of completeness we assume that there is unlimited demand for the product. Also assume that each machine takes 2 hours to process a single job.
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