L05_Batching_After - Lecture 05 Batching and Setup Times...

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Slide 1 Lecture 05 Batching and Setup Times
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Slide 2 Le arning  O bje 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.
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Slide 3 Batch Size and Capacity
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Slide 4 Batch Operations 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
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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!
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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
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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
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Slide 8 Generalize of Computation Capacity of a resource/process (time to  produce one unit) increases  with batch  size.   The largest possible capacity can be  achieved is when setup time is  eliminated (mass production). In this 
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