Operation Process Charting: How It s Made Here. APICS Fraser Valley November 2016 Presented by: Richard Ranftl (BCIT)

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1 Operation Process Charting: How It s Made Here APICS Fraser Valley November 2016 Presented by: Richard Ranftl (BCIT)

2 Manufacturing Systems What do we need to have in place to make the system functional? Input Value added Output

3 Manufacturing Systems What do we need to have in place to make the system functional? Input Value added Output

4 Have you heard of W5? Who What Where When Why

5 In Manufacturing we call it the 5W s What are we making How is it made How many do we need What do we have What do we need to go and get

6 Priority Management Techniques Strategic Business Plan Production Plan Master Production Schedule (MPS) Material Requirements Plan (MRP) Production Activity Control (PAC) Resource Requirements Plan (RRP) Rough-Cut Capacity Plan (RCCP) Capacity Requirements Plan (CRP) Input/Output Control Operation Sequencing Capacity Management Techniques

7 5W: What are we making? Bill of Materials a listing of all the subassemblies, intermediates, parts, and raw materials that go into making the parent assembly showing the quantities of each required to make an assembly

8 Bills of Material Parent Component Relationship An assembly is considered a parent, and the items that comprise it are called its component items. Table Parent Legs (4) Ends (2) Sides (2) Top (1) Hardware Kit (1) Component Item #206 Item #433 Item #711 Item #025 Item #822

9 Product Tree Garden Cart

10 BOM s: How hard can it be?

11 BOM (Reverse Engineering) Box of 12 Popsicle Box (1) Label (1) Assy (12) Popsicle (1) Bag (1) Stick (2) Water (2 oz) Orange Flavour

12 5W: How is it made? Product Routing: is the path that work follows from work centre to work centre as it is completed. It should contain: Operations to be performed Sequence of operations Work centres to be used Possible alternate work centres Tooling needed for each operation Standard times: setup times and run times per piece

13 Process Layout Factory Lathe Department Milling Department Drilling Department L L M M D D D D L L M M D D D D L L G G G P L L L L G G Grinding Department Receiving and Shipping G P Painting Department A A A Assembly

14 Product Flow in a Process Factory Order Release Queue Setup Run Wait Move Queue Setup Run Wait Move Queue Setup Run Wait Move Order Receipt 14

15 Operation Process Flow Chart Show the quantities and sequence of materials consumed in building a product (just like BOM s do) Also shows the physical steps and equipment used in putting the product together as well as the scrap losses that are expected in the production process

16 O P C Sample

17 OPC Flipped Flows like a BOM

18 Building Operation Process Flow Charts 1) Begin with most complex section 2) Horizontal line for materials 3) Identify parts by name and number 4) Vertical line for flow (briefly describe activity taking place) 5) Indicate Standard Time (and any scrap) for each Operation 6) Continue until everything listed 7) Operations should be numbered in sequence

19 Symbols: Building Operation Process Flow Charts Operation Inspection Storage

20 Subject: Muffin baking Chart begins: Raw ingredients Chart Ends: Bagged baked muffins for storage ¼ c. Shortening ½ c. Brown Sugar Creaming action (Hand) OPERATIONS PROCESS FLOW CHART 1 c. Flour 1 ½ t. Baking Powder ½ t. Baking Soda ¾ t. Salt BAKING OF BRAN MUFFIN Sifting action (Sifter) Name: Date: Type: Method: TJohnston 2008Sept20 Material Traditional ¼ c. Molasses 2 Eggs (unbeaten) Beating action (Mixer) 1 c. Milk 2 Cups Bran Mixing action (Mixer) 0.60 ½ c. Raisins (optional) SA10 Mixing action (Mixer) Muffin Cups SA20 Spoon into cups (Muffin Tin) SA30 Bake at 425 F (Oven) SA40 Cooling (Rack) Plastic Bag P10 Package (Hand)

21 Leads into an analysis of Operational Capacity: - What resources are available (what do we have / what do we have to go get) - How will materials flow through the plant (point of use storage requirements / flow or batch processing) - Organizing flow to optimize operations (arranging for maximum productivity)

22 Priority Management Techniques Strategic Business Plan Production Plan Master Production Schedule (MPS) Material Requirements Plan (MRP) Production Activity Control (PAC) Resource Requirements Plan (RRP) Rough-Cut Capacity Plan (RCCP) Capacity Requirements Plan (CRP) Input/Output Control Operation Sequencing Capacity Management Techniques

23 OPC Leads to Rolled Throughput Yield Analysis We can OPC/RTY information for: - Volumes (and space) in the plant (machinery) - Volumes (and space) for Raw Materials - Volumes (and space) for Finished Goods - Materials Handling Equipment - Storage Space requirements - Manpower Planning - And

24 Rolled Throughput Yield: Scrap and Yield (refresher) Yield for one operation is 90% (10% are scrapped). Suppose we put 100 parts in to the operation. How many do we get out? 100 *.90 = 90 good units (yield) 10 reject units (scrap)

25 RTY: Rolled Throughput Yield Rolled throughput yield (RTY) is the product of the combined sequence of yield values: 90% * 90% = 81%. Suppose we have five sequential operations each with a scrap rate of 10%, what is the RTY of that system?.9 *.9 *.9 *.9 *.9 = (which is 59.0%)

26 RTY: Rolled Throughput Yield How many would need to be started at each stage of the five operations in order to get 100 good units out? (90% yield at each stage) Stage 1) out means /.9 in = Stage 2) out means /.9 in = Stage 3) out means /.9 in = Stage 4) out means /.9 in = Stage 5) out means /.9 in = (Cross-check / = )

27 Material Requirements Example Eg: 4 Feet needed per chair (p/n 2000) 4 pieces * 40 chairs per hour = 160 pieces per hour 160 per hour * 8 hrs per day = 1,280 pieces per day 1,280 per day * 5 days per week = 6,400 pieces per week What about Scrap? The real volume we need must be adjusted for the RTY, so we really need: 6,400 / = 6,732.6 pieces per week

28 Product Storage Requirements

29 Metal Shop in Confident Chair

30 Equipment Requirements Example (work area) Using that same logic for the 4 operations needed to make Lower Legs: 10 Cut Steel to Length hrs Press 20 Form to shape hrs Press 30 Form round for Foot hrs Press SSA10 Attach Foot hrs Press TOTAL TIME: hrs Press At 90% operator efficiency we will need to do hrs of Press work in a one hour time period, therefor we need Presses to make Lower Legs

31 Factory Layout Planning OPC will identify critical relationships for facility layout planning

32 Factory Layout Planning OPC will identify critical relationships for facility layout planning

33 Manpower Requirements Based on how you were able to lay out the work cells (to take advantage of common resources) you should be able to develop a list of Production Employees that are needed to man the various pieces of equipment. Example: 3 workers needed in Lower Leg Assembly to operate the three presses

34 Materials Handling: Simulate the Flow OPC and RTY will indicate the volume of flow, we can then load materials handling equipment.

35 Importance of Capacity Decisions - Impacts ability to meet future demands - Affects operating costs - Major determinant of initial costs - Involves a long-term commitment - Affects competitiveness

36 Question Period Best Textbook (that I have found):

37 Operation Process Charts Session Summary - Production Routing is detailed in the Operations Process Flowchart - Provides much more detail (times / resource requirements / scrap rates) than the BOM - Aids in diagramming the production flow and in preparing for capacity calculations

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