L05_Batching_After - Slide 1 Lecture 05 Batching and Setup...

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Unformatted text preview: Slide 1 Lecture 05 Batching and Setup Times Slide 2 Le a rning O b je c tive s Understand the characteristics of batch process. Understand the major trade-offs involved in batch size decisions. Compute the best batch size for different scenarios and correspond performance measures. Understand techniques to reduce setups. Slide 3 Batch Size and Capacity Slide 4 Batch Operations A production batch is a collection of flow units that are processed before the resource (usually the equipment being used at that step) needs to go through another setup. Set up Interruption of process flow Reduction of capacity Slide 5 GM Producing Doors for a Car Setup the line for left doors Produce left doors Produce right doors Setup the line for left doors 50min 2min/door 50min 2min/door Production Stops! Slide 6 Batch of 5 Batch of 25 Batch of 50 Batch of 150 Time [minutes] 50 100 150 200 250 Shift from left to right Shift from right to left Produce right door (1 box corresponds to 5 units = 5 doors) Produce left door (1 box corresponds to 5 units = 5 doors) Production cycle Production cycle The Impact of Set-ups on Capacity 10min 50min 10min 50min Slide 7 The Impact of Set-ups on Capacity Batch size Time to Complete 1 Batch (min) Capacity (units/min) 5 50 (set up left) + 10 (produce left) + 50 (setup right) + 10 (produce right) 5/120 = 0.0417 120 minutes 25 50 (set up left) + 50 (produce left) + 50 (setup right) + 50 (produce right) 25/200 = 0.125 200 minutes 50 50 (set up steering support) + 100 (produce steering supports) + 50 (setup ribs) + 100 (produce ribs) 50/300 = 0.167 300 minutes 150 50 (set up steering support) + 300 (produce steering supports) + 50 (setup ribs) + 300 (produce ribs) 150/700 = 0.214 700 minutes Slide 8 Generalize of Computation Capacity of a resource/process (time to produce one unit) increases with batch...
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L05_Batching_After - Slide 1 Lecture 05 Batching and Setup...

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