Date post: | 06-Apr-2018 |
Category: |
Documents |
Upload: | mayank-soni |
View: | 239 times |
Download: | 0 times |
of 32
8/3/2019 Batch Flow Process
1/32
BATCH FLOW PROCESSBATCH FLOW PROCESS
Course InstructorCourse Instructor
Dr. N. SambandamDr. N. Sambandam
______________________________________________________________________________________________
NATIONAL INSTITUTE OF INDUSTRIAL ENGINEERINGNATIONAL INSTITUTE OF INDUSTRIAL ENGINEERING
ViharVihar Lake, Mumbai 400 087.Lake, Mumbai 400 087.
8/3/2019 Batch Flow Process
2/32
PRODUCTS AND VOLUMEPRODUCTS AND VOLUME
Produce low volumes of variety of differentproducts.
Investment in specialized machines andtools is justified.Orders: one time for small qty. and repeat fromtime to time.
ExamplesExamples: Home heating systems, Tanks formilitary, Ice cream, Forest harvest equipments,Suit coat, sport coat, Kitchen & dinning room
furniture,Pharmaceutical products.
8/3/2019 Batch Flow Process
3/32
LAYOUT AND MATERIAL FLOWLAYOUT AND MATERIAL FLOW
Cellular layout/Functional layout.Employees work in more than one department and are skilled
on many equipments.Equipment and tooling are special purpose a (lower overhead).Material flow through the shop do not differ for each job.Work-in-process inventory is low.Delivery times are not long.
Setup time is low.Batch (or lot) size decides the workload in the shop.Scheduling is important but is simpler than job shop.
8/3/2019 Batch Flow Process
4/32
Materialsordering
Spreading
Reproducingthe marker
CuttingFitting andSoabaring
Fitting
Fitting
Materialsreceipts
Majormatching
Subassembly
Subassembly
Othersubassembly
Majormatching
Finalassembly
Pressingand
inspection
sleeves
fronts
backs
collars
Welts, etc
To coatshop
To skirtshop
CoatShop
Serging
Outside pleating
RemainingSkirt operations
Pressing andinspection
Warehouse matchingOf coat and skirt
Skirtshop
Todistributor
Figure: a Simplified process flow diagram
8/3/2019 Batch Flow Process
5/32
Operations flow chartOperations flow chart
Shoulderjoint
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
6/32
Operations descriptionOperations description
Work station #4 , operation: TrimmingWork station #4 , operation: Trimming
A set of collar parts is taken from stand and put onA set of collar parts is taken from stand and put onthe LHS area of the work stationthe LHS area of the work station
A collar neck band part is taken by left handA collar neck band part is taken by left hand The part is put under the presser foot of trimmingThe part is put under the presser foot of trimming
m/c by using both hands.m/c by using both hands.
The part is trimmed by machine by pivoting itThe part is trimmed by machine by pivoting it
wherever necessarywherever necessary The trimmed part is put on legs by right handThe trimmed part is put on legs by right hand
A batch of trimmed parts is taken from legs and putA batch of trimmed parts is taken from legs and puton the standon the stand
8/3/2019 Batch Flow Process
7/32
Determination ofDetermination of smvsmv &&
ThroughputThroughput TotalTotal smvsmv= sum of all ten readings(seconds)/60= sum of all ten readings(seconds)/60
AverageAverage smvsmv= Total= Total smvsmv/10/10
Std time =Std time = AvgAvg time(time(avgavg smvsmv)*allowance)*allowance
Allowance = 15% (for machine operation)Allowance = 15% (for machine operation)= 12%(for manual operation)= 12%(for manual operation)
Capacity per hour(Throughput)= 60/std timeCapacity per hour(Throughput)= 60/std time
8/3/2019 Batch Flow Process
8/32
Path lengthPath lengthpath: collar to end line(length= 10.53 m)path: collar to end line(length= 10.53 m)
Shoulderjoint
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
9/32
Path : collar band to end line checkingPath : collar band to end line checkinglength= 9.05 minuteslength= 9.05 minutes
Shoulderjoint
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
10/32
Path: front right to end line checkingPath: front right to end line checkingpath length= 9.62 minutespath length= 9.62 minutes
Shoulderjoint
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
11/32
Path: front right to end line checkingPath: front right to end line checkingpath length= 9.56 minutespath length= 9.56 minutes
Shoulderjoint
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
12/32
Path: pocket to end line checkingPath: pocket to end line checkingpath length= 10.37 minutespath length= 10.37 minutes
Shoulderjoint
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
13/32
Path: back to end line checkingPath: back to end line checkingpath length= 9.764 minutespath length= 9.764 minutes
Shoulderjoint
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
14/32
Path: sleeve placket to end linePath: sleeve placket to end linecheckingchecking
path length= 8.68 minutespath length= 8.68 minutesCollar trim Collar run Collar trim Collar turn Collar
edge levelCollar iron Collar top
Band hem Band set Band set
top
Collar
inspection
Plackettrim
Frontplacket
Frontbutton hole
Pocketattach
Pocketiron
Pocketiron & trim
Pockethem
Main labelattach Small labelattach Yokeattach Yoke iron& trim
Shoulderjoint
Sleeveplacket
SleeveBartac
Sleeve boxSleeve
button hole
Cuff hem Cuff runCuff turn& edge
Cuff top
Collar attach
Collar finishing
Sleeve attach
Sleeve top
Side seam
Cuff matchingand marking
Checking &trimming
Frontbuttonattach
Buttonmarking
Collar &cuff button
holeBottom
hemCuff attach
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
15/32
Path: cuff to end line checkingPath: cuff to end line checkingpath length= 6.113 minutespath length= 6.113 minutes
Collar trim Collar run Collar trim Collar turn Collaredge level
Collar iron Collar top
Band hem Band set Band set
top
Collar
inspection
Plackettrim
Frontplacket
Frontbutton hole
Pocketattach
Pocketiron
Pocketiron & trim
Pockethem
Main labelattach Small labelattach Yokeattach Yoke iron& trim
Shoulderjoint
Sleeveplacket
SleeveBartac
Sleeve boxSleeve
button hole
Cuff hem Cuff runCuff turn& edge
Cuff top
Collar attach
Collar finishing
Sleeve attach
Sleeve top
Side seam
Cuff matchingand marking
Checking &trimming
Frontbuttonattach
Buttonmarking
Collar &cuff button
holeBottom
hemCuff attach
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
16/32
Critical pathCritical path
The path having maximum time lengthThe path having maximum time length
i.e. if all the parts of the shirt are put into the line fori.e. if all the parts of the shirt are put into the line fortheir respective operations at the same time thentheir respective operations at the same time thenthe part which is coming through the path which isthe part which is coming through the path which istaking maximum time will decide the throughputtaking maximum time will decide the throughputtime of the line , this path is called as critical pathtime of the line , this path is called as critical path
So here critical path: the path coming from collar toSo here critical path: the path coming from collar toend line checkingend line checking
Critical path length= 10.53 minutesCritical path length= 10.53 minutes
8/3/2019 Batch Flow Process
17/32
Critical pathCritical pathcritical path length=10.53 minutescritical path length=10.53 minutes
Collar trim Collar run Collar trim Collar turn Collaredge level
Collar iron Collar top
Band hem Band set Band set
top
Collar
inspection
Plackettrim
Frontplacket
Frontbutton hole
Pocketattach
Pocketiron
Pocketiron & trim
Pockethem
Main labelattach Small labelattach Yokeattach Yoke iron& trim
Shoulderjoint
Sleeveplacket
SleeveBartac
Sleeve boxSleeve
button hole
Cuff hem Cuff runCuff turn& edge
Cuff top
Collar attach
Collar finishing
Sleeve attach
Sleeve top
Side seam
Cuff matchingand marking
Checking &trimming
Frontbuttonattach
Buttonmarking
Collar &cuff button
holeBottom
hemCuff attach
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
18/32
Work balancing among workWork balancing among workstations to achieve the requiredstations to achieve the required
targettarget Search for the bottleneck operationsSearch for the bottleneck operations
Bottleneck decides the capacity of theBottleneck decides the capacity of thelineline
E.g. what is the capacity of this line?E.g. what is the capacity of this line?
Op1(100) Op2(90) Op3(115) Op4(120)
8/3/2019 Batch Flow Process
19/32
Work balancing.Work balancing. continuedcontinued
Operation with least capacity isOperation with least capacity is
sleeve placketsleeve placket
SMV=1.18 minutesSMV=1.18 minutesCapacity = 44 units per hourCapacity = 44 units per hour
But it will not be considered asBut it will not be considered asbottleneck because it does not lie onbottleneck because it does not lie onthe critical paththe critical path
8/3/2019 Batch Flow Process
20/32
Critical pathCritical pathcritical path length=10.53 minutescritical path length=10.53 minutes
Collar trim Collar run Collar trim Collar turn Collaredge level
Collar iron Collar top
Band hem Band set Band set
top
Collarinspection
Plackettrim
Frontplacket
Frontbutton hole
Pocketattach
Pocketiron
Pocketiron & trim
Pockethem
Main labelattach Small labelattach Yokeattach Yoke iron& trim
Shoulderjoint
Sleeveplacket
SleeveBartac
Sleeve boxSleeve
button hole
Cuff hem Cuff runCuff turn& edge
Cuff top
Collar attach
Collar finishing
Sleeve attach
Sleeve top
Side seam
Cuff matchingand marking
Checking &trimming
Frontbuttonattach
Buttonmarking
Collar &cuff button
holeBottomhem
Cuff attach
Path from sleeve
placket have thelead of 1.84 mover the critical
pathLeast
capacitySMV=1.1
8 m &capacity
=44 u ph
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
21/32
Work balancing Work balancing Next operation having the least capacityNext operation having the least capacity
Cuff attachCuff attach
SMV = 1.145 minutesSMV = 1.145 minutes
Capacity = 45 units per hourCapacity = 45 units per hour
It lies on the critical pathIt lies on the critical path
So considered as bottleneck operationSo considered as bottleneck operation
So affects the line capacity, because changes in theSo affects the line capacity, because changes in thesmvsmv value of this operation will have effect onvalue of this operation will have effect on
critical path lengthcritical path length
8/3/2019 Batch Flow Process
22/32
Work balancing..Work balancing..Ways to improve bottleneckWays to improve bottleneck
capacitycapacity
a.a. Put an extra work stationPut an extra work station
it will causeit will cause smvsmv to be half andto be half anddouble the capacitydouble the capacity
b.b. Distribute the excess work to theDistribute the excess work to theother work stations(it is being appliedother work stations(it is being appliedcurrently)currently)
8/3/2019 Batch Flow Process
23/32
Distributing the excess work toDistributing the excess work to
other work stations in the lineother work stations in the line Required capacity = 69 units per hourRequired capacity = 69 units per hour
Current production = 45 units per hourCurrent production = 45 units per hour
Work remained= 69Work remained= 69--45= 24 units per hour45= 24 units per hour extra time required= 24*1.145*1.15=extra time required= 24*1.145*1.15=
31.6 minutes = 31 minutes 36 seconds31.6 minutes = 31 minutes 36 seconds
Looking at the operation flow chart for the workLooking at the operation flow chart for the workstation having operation running at over capacitystation having operation running at over capacity
Band hem is that operationBand hem is that operation
capacity= 315 units per hourcapacity= 315 units per hour
8/3/2019 Batch Flow Process
24/32
Distribution of work .Distribution of work .
Band hemBand hem Minimum required units to be produced= 85 unitsMinimum required units to be produced= 85 units
per hourper hour
time required to do band hem operation on 85time required to do band hem operation on 85units= (1/315)*85= 0.27 hours = 16.19 minutesunits= (1/315)*85= 0.27 hours = 16.19 minutes= 16 minutes 11.4 seconds= 16 minutes 11.4 secondsextra time available = 43 minutes 48.6 secondsextra time available = 43 minutes 48.6 seconds
For cuff attach we require 31 minutes 36 secondsFor cuff attach we require 31 minutes 36 secondsSo we can accommodate it hereSo we can accommodate it here
still time available = 12 minutes 12.5 secondsstill time available = 12 minutes 12.5 seconds
8/3/2019 Batch Flow Process
25/32
Search for next bottleneckSearch for next bottleneck
Cuff run is the next operation having least capacityCuff run is the next operation having least capacity
But it cant be said as a bottleneck operationBut it cant be said as a bottleneck operationbecause it doesnt lie on the critical pathbecause it doesnt lie on the critical path
The sub path is having lead of 4.412 minutes overThe sub path is having lead of 4.412 minutes overits counter path on the junction operationits counter path on the junction operation
So the delay caused by the cuff run operation willSo the delay caused by the cuff run operation willbe compensated by the lead timebe compensated by the lead time
8/3/2019 Batch Flow Process
26/32
Operation = cuff runOperation = cuff run
Collar trim Collar run Collar trim Collar turn Collaredge level
Collar iron Collar top
Band hem Band set Band set
top
Collarinspection
Plackettrim
Frontplacket
Frontbutton hole
Pocketattach
Pocketiron
Pocketiron & trim
Pockethem
Main labelattach Small labelattach Yokeattach Yoke iron& trim
Shoulderjoint
Sleeveplacket
SleeveBartac
Sleeve boxSleeve
button hole
Cuff hem Cuff runCuff turn& edge
Cuff top
Collar attach
Collar finishing
Sleeve attach
Sleeve top
Side seam
Cuff matchingand marking
Checking &trimming
Front
buttonattach
Buttonmarking
Collar &
cuff buttonhole
Bottomhem Cuff attach
Leastcapacity
= 51uphsmv=1.0
1 mSub path viacuff run is
having leadtime = 4.412m over its
counter path
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
27/32
Search for the nextSearch for the nextbottleneckbottleneck
Sleeve topSleeve top Capacity=58 units per hourCapacity=58 units per hour
SMV= 0.88 minutesSMV= 0.88 minutes
Extra units to beExtra units to be operationalisedoperationalised = 11 units per hour= 11 units per hour
Time required to do sleeve top operation on 11 units =Time required to do sleeve top operation on 11 units =11*0.88*1.15 = 11 minutes 8 seconds11*0.88*1.15 = 11 minutes 8 seconds
3 options3 options
We can accommodate it on the work station at whichWe can accommodate it on the work station at which
band hem is being doneband hem is being done Put an extra work stationPut an extra work station
Search for another work station which is running onSearch for another work station which is running onover capacityover capacity
8/3/2019 Batch Flow Process
28/32
Search for the work stationSearch for the work station
running at over capacityrunning at over capacity Main label attachmentMain label attachment
Capacity = 206 units per hourCapacity = 206 units per hour
SMV= 0.26 minutesSMV= 0.26 minutes Required capacity = 142 units per hourRequired capacity = 142 units per hour
Time require for 142 unit = 142*1.15*0.26= 41Time require for 142 unit = 142*1.15*0.26= 41minutes 38.4 secondsminutes 38.4 seconds
Extra time available= 19 minutes 21.6 secondsExtra time available= 19 minutes 21.6 seconds So we can accommodate the 11 units per hour forSo we can accommodate the 11 units per hour for
the sleeve top operationthe sleeve top operation
Still the time available = 8 minutes 13 secondsStill the time available = 8 minutes 13 seconds
8/3/2019 Batch Flow Process
29/32
Improvement in the lineImprovement in the linecapacitycapacity
Current capacity = 550 units per shiftCurrent capacity = 550 units per shift
Projected improvement=10% or 56 unitsProjected improvement=10% or 56 units
per shiftper shift New projected capacity = 606 units perNew projected capacity = 606 units per
shiftshift
Per hour capacity = 76 unitsPer hour capacity = 76 units
So the bottleneck operation will be theSo the bottleneck operation will be theoperation running on the capacity less thanoperation running on the capacity less than
76 units per hour76 units per hour
8/3/2019 Batch Flow Process
30/32
Critical path length= 10.017Critical path length= 10.017minutesminutes
Collar trim Collar run Collar trim Collar turn Collaredge level
Collar iron Collar top
Band hem Band set Band set
top
Collarinspection
Plackettrim
Frontplacket
Frontbutton hole
Pocketattach
Pocketiron
Pocketiron & trim
Pockethem
Main labelattach Small labelattach Yokeattach Yoke iron& trim
Shoulderjoint
Sleeveplacket
SleeveBartac
Sleeve boxSleeve
button hole
Cuff hem Cuff runCuff turn& edge
Cuff top
Collar attach
Collar finishing
Sleeve attach
Sleeve top
Side seam
Cuff matchingand marking
Checking &trimming
Front
buttonattach
Buttonmarking
Collar &
cuff buttonhole
Bottomhem Cuff attach
Frontpairing
Buttonplacket
8/3/2019 Batch Flow Process
31/32
Operations with capacity
8/3/2019 Batch Flow Process
32/32