Manufacturing reduce setup times and production lot

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Manufacturing Reduce setup times and production lot sizes Change the layout of the factory to allow streamlines product flows through the plant Convert clusters of machines within process-focused layouts to cellular manufacturing (CM) centers or cells. In CM, groups of machines function as product-focused islands within the larger layout. Install flexible manufacturing systems (FMS). These groups of machines can accommodate product variety without the necessity of worker- performed machine changeovers. Standardize parts designs to reduce the number of parts and the number of changeovers. Train workers for several jobs. Theses flexible workers can move from work center to work center as necessary to balance the workload in the factory. Install effective preventive maintenance programs so that machine breakdowns do not interrupt product flows. Install effective quality control programs so that defective products do not interrupt product flows. Develop an effective subcontractor network so that materials flow into factory smoothly to support the in-house production schedule, thereby allowing uninterrupted production.
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Example: Timely Production Timely production (TP) runs a production shop with 5 machines that produce 2 different products. A and B. the market can absorb all the products generated by this system. This facility is shown in Figure a below. Product A requires machines I, III, and IV. Product B requires machines II, III, and V. Processing times on machines I, II, Iv and V are two hours per product, while the processing time on machine III is one hour per unit of A and one hour per unit of B. 1. Which machine (or machines) represent a production constrain at TP? 2. Is it possible to have a LT/PT ratio of 1.0 for this system? Explain by drawing a complete production cycle on the Grant Chart in Figure 2. 3. If there is a set up of 1 hour on machine III to change between products, do your answers to questions 1 and 2 change? Explain. If TP decides, given this set up time, to produce in batch sizes of 5 for both products A and B, what will be the resulting LT/PT? What will be the resulting LP/TP for a batch size of 50 for each product? Does the batch size make a difference in terms of how many total products can be produced in a 40 hour week? 4. Identify practical reason why TP would routinely maintain buffers in front of each machine.
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I II III IV V RM A RM B A A B B Figure 1 2 hours/unit 2 hours/unit 2 hours/unit 2 hours/unit 1 hours/unit
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Machine 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 …… …… …… …… …… …… …… …… …… …… …… …… …… …… …… ..... ........ ... 22 23 I A1 A 1 A 2 A 2 ……………………… A 5 A 5 ……… II B 1 B 1 B 2 B 2 ………………………. . B 5 B 5 B 5 III A 1 B 1 A 2 B 2 A 5 IV A 1 A 1 A 2 A 2 A 5 A 5 V B 1 B 1 B 2 B 2 B 5 B 5 Question (2): Assume: Setup Time = 0 (machine – 3) Lotsize = 1 For both A and B: Total Processing Time = 5 Total Lead time= 5 So, LT/PT Ratio = 1 Production rate = 40 units/ hour
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Question (3) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
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