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Impact of Setup/Changeover Time On Capacity. Inventory, and Flow Time

1. The document analyzes the impact of setup/changeover time on production capacity, inventory levels, and flow time for 8 injection molded parts produced in a cyclic order over 30 days. 2. Key inputs include a setup/changeover time of 1,400 minutes between parts and 24 hours of operating time per day. 3. The results show that with a setup/changeover time of 64 hours per month, the effective production time is 656 hours per month, which meets the monthly demand of 1,000 units for each product while maintaining average inventory and flow time. Setup time represents about 9% of the total time, production time is 65%, and idle time is 26%.

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Ramalingam Govindarasu
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270 views

Impact of Setup/Changeover Time On Capacity. Inventory, and Flow Time

1. The document analyzes the impact of setup/changeover time on production capacity, inventory levels, and flow time for 8 injection molded parts produced in a cyclic order over 30 days. 2. Key inputs include a setup/changeover time of 1,400 minutes between parts and 24 hours of operating time per day. 3. The results show that with a setup/changeover time of 64 hours per month, the effective production time is 656 hours per month, which meets the monthly demand of 1,000 units for each product while maintaining average inventory and flow time. Setup time represents about 9% of the total time, production time is 65%, and idle time is 26%.

Uploaded by

Ramalingam Govindarasu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
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Impact of Setup/Changeover Time on Capacity.

Inventory, and Flow Time


Sunil Chopra 2/20/03

Assumptions:
1. There are 8 different injection molded parts to be produced for Toyota
2. The plant runs for 30 days a month
3. Changeover time between any pair of products is the same
4. Products are produced in a cyclic order from 1-8 and again 1-8

Inputs
Setup/Changeover Time
Operating Time / Day
Duration of a Production Cycle

1,400
1,200

8 hours
24 hours
720 hours

1,000
800
600

Feasible

400
200
0

Minimum Cycle Duration (1 unit each)


Product
Production Rate (units/hour)
Monthly Demand
Results
Production Time / Month
Number of Production Cycles / Month
Number of Changeovers / Month
Changeover Time / Month
Minimum Production Time Required
Effective Production Time / Month
Product
Production Time / Cycle (hours)
Production Batch / Cycle (units)
Average Inventory
Average Flow Time (days)
Maximum Monthly Production
Is Demand Met?

Production Time / Month


Changeover Time / Month

Product 1 Demand

64.47 hours
1
17
1,000

2
17
1,000

720 hours
1.00
8.00
64.00 hours
470.59
656.00 hours
1
2
82.00
82.00
1,394.0 1,394.0
697.0
697.0
20.91
20.91
1,394
1,394
Yes
Yes

720
64.00

3
17
1,000

4
17
1,000

5
17
1,000

6
17
1,000

Maximum Monthly
Production

7
17
1,000

800
700
600
500
400
300
200
100
0

Produc tion
T ime / Month

3
82.00
1,394.0
697.0
20.91
1,394
Yes

Changeover
T ime / Month

4
5
6
7
82.00
82.00
82.00
82.00
1,394.0 1,394.0 1,394.0 1,394.0
697.0
697.0
697.0
697.0
20.91
20.91
20.91
20.91
1,394
1,394
1,394
1,394
Yes
Yes
Yes
Yes

Effec tive
Produc tion
T ime / Month

Effective Production Time / Month


Product 1 Demand
Maximum Monthly Production
Setup time (as a fraction of total)
Production time (as a fraction of total)
Idle time

656.00
1,000
###
0.08889
0.65359
0.25752

Sunil Chopra 2/20/03

over
Month

Maximum Monthly
Production

8
17
1,000

Effec tive
Produc tion
T ime / Month

8
82.00
1,394.0
697.0
20.91
1,394
Yes

Setup time (as a fraction of total)


Production time (as a fraction of total)
Idle time

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