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4c.throughput Setup 2022-Part2

Throughput Analysis part 2

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Francis Nyeko
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4 views

4c.throughput Setup 2022-Part2

Throughput Analysis part 2

Uploaded by

Francis Nyeko
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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A Process with Three Stations

e) Suppose we have replaced the recourse unit of Sta-1. The new resource
does not need setup, but its processing time is increased to 0.5. Suppose the
setup time of Sta-2, is at the original time of 20 mins per batch. Compute the
capacity of the process.
Process Steps Sta-1 Sta-2 Sta-3
Setup Time (mins) 0 30 20
Processing Time (mins) 0.5 0.25 0.2
Sta-3 will always have safety capacity compared to the capacity of Sta-2.
We only need to compare Sta-2 and Sta-1.
30+0.25Q = 0.5Q
30=0.25Q  Q=120
For batch sizes less than 120, the cycle time is 0.25+30/Q. Which is >0.5.
At Q= 120, bottleneck shifts to station 1. Cycle time becomes 0.5 minute.
For batch sizes greater than or equal to 120, the process capacity is 2 per
minute
Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 1
A Process with Three Stations
f) Consider the following situation. Process Steps
Sta-1 Sta-2 Sta-3
Setup Time (mins) 45 0 20
Processing Time (mins) 0.15 0.25 0.2
Suppose all the flow units of a batch need to be processed at a resource
before any of the units of the batch can be moved to the next resource.

Compute the minimal batch size to maximize the process capacity. That is the
batch size which minimizes the inventory.
0.25Q=45+0.15Q  0.1Q=45  Q=450
0.25Q=20+0.2Q  0.05Q=20  Q=400
If batch size is set to 400, then Sta-1 cannot produce as much as Sta-3 needs.
The minimal batch size to maximize the process capacity is Q=450.
Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 2
A Process with Three Stations
g) Consider the following situation. Process Steps
Sta-1 Sta-2 Sta-3
Setup Time (mins) 45 0 20
Processing Time (mins) 0.15 0.25 0.2
Suppose all the flow units of a batch need to be processed at a resource
before any of the units of the batch can be moved to the next resource.
Suppose demand is 60 per hour. Compute the batch size to minimize the flow
time.
Procedure 1. Batch Production Time Procedure 2. Takt Time
60 per hour is 1 per minute 60 per hour  Takt time = 1 minute
45+0.15Q=1Q 0.85Q=45  Q= 45/Q+0.15=1 45/Q=0.85  Q=
52.94=53 52.94=53
20+0.2Q=1Q 0.8Q=20  Q=25 20/Q+0.2=1 20/Q =0.8  Q=25
Therefore Q=53 Therefore Q=53
Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 3
A Process with Three Stations
Selling high quality ice cream to restaurants
Ice cream Strawberry(S) Chocolate (C) Vanilla (V)
Demand (kg per hr) 10 15 5
Setup Time (hrs) 3/4 1/2 1/6

The sequence of production is St, Ch, Va. Capacity of the machine for each
type of ice-cream is 50 pounds per hour.
Lets define a batch a combination of the three product in the same proportion
as demand. That is 10, 15, and 5 = 30. We can define a 1 pound of this batch
as 10/30, 15/30, and 5/30 pound of the three types. That is 1/3, 0.5, and 1/6
pound in one pound.
We need 10+15+5= 30 kg per hr. TT= 1/30 hr or TT=2 minutes.
We need a setup time of 3/4 +1/2+1/6 = 17/12 hours. That is 60(17/12) = 85
mins.
We can produce this at a rate of 50 kg per hour. ThTp=60/50= 1.2 mins
Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 4
A Process with Three Stations
1/3, 0.5, and 1/6 in one kg.
Demand one per 2 mins
Setup time 85 mins.
ThTp= 1.2 mins
Procedure 1. Break-Even Analysis
85+1.2Q=2Q  85=0.8Q  Q=106.25
Procedure 2. Tp=TT
Tp= 85/Q+1.2 = 2  85/Q=0.8  Q=106.25
Procedure 3. Rp=R
R= 0.5 per min
Rp=Q/(85+1.2Q) = 0.5  Q= 0.5(85+1.2Q)  Q=42.5+0.6Q 0.4Q=42.5
Q=106.25
How much of each type of ice cream do we produce per batch
Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 5
A Process with Three Stations
1/3, 0.5, and 1/6 in one kg.
106.25 (1/3, 0.5, 1/6) = 35.417, 53.125, 17.708
Compute the average inventory of Chocolate ice cream
Production at rate of 50/60 = 5/6 per minute
Consumption at rate of 15/60 = 0.25 per minute
It takes 53.125/(5/6)= 63.75 mins to produce this batch of chocolate ice
cream
Max-WIP-Ch = We produce at rate of 5/6 and consume at rate of 0.25 for
63.75 mins
Max-WIP-Ch= 63.75(5/6-0.25) = 37.1875
Average Inventory = 18.6

Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 6


Two Parts
Two parts. Tp=1 for each unit of each part. 60 mins setup time of each part.
Demand of the downstream station is 24 per hour. Batch size is 240.
Setup for 60 mins produce 240 units of part-1 (takes 240 mins).
Setup for 60 mins produce 240 units of part-2 (takes 240 mins).
Tp1=Tp2=60/240+1=1.25 CT=1.25
Rp1=Rp2= 240/(60+240)= 0.8 units per min or 48 per hr
R=24 /hr R=0.4 per min  TT=2.5 mins.
Setup for 60 mins, and produce 240 units in 240 minutes.
Over the 240 mins, we consume 0.4 per mins, that is 96 units. Therefore the
maximum inventory is 240-96=144 units. We consume this 144 mins in
144/0.4 = 360 mins. We need to restart the next setup when we have
0.4(60)=24 units.
Setup for 60 mins. Produce for 240 mins, consume for 300 mins, restart set
up after 600 mins. When we start part-2? Part 2 should re-setup
Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 7
Throughput Loss, Limited Buffer, Blocking

Station-1 Station-2 Station-3

Rp=80 /hr Rp=100 /hr Rp=120 /hr


Every 4 hours
30 mins cleaning

No buffer anywhere. Compute the capacity of the process.


Rp2=(4*100)/(4+0.5)= 88.89
Is capacity of the process 80 per hour? No buffer anywhere.
For 30 minutes cleaning of Station-2, Station-1 has no place to put the output.
It is blocked for 0.5 hours.
Rp2=(4*80)/(4+0.5)= 71.1
Place a buffer for 40 product between Station-1 and Station-2.
Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 8
Throughput Loss, Limited Buffer, Starvation

Station-1 Station-2 Station-3

Rp=120 /hr Rp=100 /hr Rp=80 /hr


Every 4 hours
30 mins cleaning

No buffer anywhere. Compute the capacity of the process.


Rp2=(4*100)/(4+0.5)= 88.89
Is capacity of the process 80 per hour? No buffer anywhere.
For 30 minutes cleaning of Station-2, Station-3 has no product to work on.
Starvation
Rp2=(4*80)/(4+0.5)= 71.1
Place a buffer for 40 product between Station-2 and Station-3.
Impact of Setup Time on Throughput & Flow Time, Ardavan Asef-Vaziri. 9

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