Operation Process Charting: How It s Made Here APICS Fraser Valley November 2016 Presented by: Richard Ranftl (BCIT)
Manufacturing Systems What do we need to have in place to make the system functional? Input Value added Output
Manufacturing Systems What do we need to have in place to make the system functional? Input Value added Output
Have you heard of W5? Who What Where When Why
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
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
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
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
Product Tree Garden Cart
BOM s: How hard can it be?
BOM (Reverse Engineering) Box of 12 Popsicle Box (1) Label (1) Assy (12) Popsicle (1) Bag (1) Stick (2) Water (2 oz) Orange Flavour
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
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
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
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
O P C Sample
OPC Flipped Flows like a BOM
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
Symbols: Building Operation Process Flow Charts Operation Inspection Storage
Subject: Muffin baking Chart begins: Raw ingredients Chart Ends: Bagged baked muffins for storage ¼ c. Shortening ½ c. Brown Sugar 2.67 10 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 0.67 40 Sifting action (Sifter) Name: Date: Type: Method: TJohnston 2008Sept20 Material Traditional ¼ c. Molasses 2 Eggs (unbeaten) 0.75 20 Beating action (Mixer) 1 c. Milk 2 Cups Bran 0.15 30 Mixing action (Mixer) 0.60 ½ c. Raisins (optional) SA10 Mixing action (Mixer) 0.80 12 Muffin Cups SA20 Spoon into cups (Muffin Tin) 14.50 SA30 Bake at 425 F (Oven) 20.00 SA40 Cooling (Rack) 0.33 1 Plastic Bag P10 Package (Hand)
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)
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
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
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)
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 =.59049 (which is 59.0%)
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) 152.42 out means 152.42/.9 in = 169.35 Stage 2) 137.17 out means 137.17/.9 in = 152.42 Stage 3) 123.46 out means 123.46/.9 in = 137.17 Stage 4) 111.11 out means 111.11/.9 in = 123.46 Stage 5) 100.00 out means 100.00/.9 in = 111.11 (Cross-check 100.00 /.59049 = 169.35)
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 / 0.9506 = 6,732.6 pieces per week
Product Storage Requirements
Metal Shop in Confident Chair
Equipment Requirements Example (work area) Using that same logic for the 4 operations needed to make Lower Legs: 10 Cut Steel to Length 0.5610 hrs Press 20 Form to shape 0.7481 hrs Press 30 Form round for Foot 0.3740 hrs Press SSA10 Attach Foot 0.9351 hrs Press TOTAL TIME: 2.6182 hrs Press At 90% operator efficiency we will need to do 2.6182 hrs of Press work in a one hour time period, therefor we need 2.6182 Presses to make Lower Legs
Factory Layout Planning OPC will identify critical relationships for facility layout planning
Factory Layout Planning OPC will identify critical relationships for facility layout planning
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
Materials Handling: Simulate the Flow OPC and RTY will indicate the volume of flow, we can then load materials handling equipment.
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
Question Period Best Textbook (that I have found):
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