F leming

Consulting, LL
Takt Time

OEE

Planned Cycle Time

EPEI

Capacity Analysis

Machine Capacity Check

Lot Formation Capacity Check

Single Stack

OBC

www.fleming-consulting.com
 leming
Consulting, LLC
Stacked OBC Standard Work In Process

Minimum Manning Motion Economy Chart

Value Added Ratio

Kanban
Click on this symbol
Pitch =
to return home
Average Cycle Time

FPY

Productivity

Inventory Turns

www.fleming-consulting.com
Takt Time Calculation =
F
Enter the following information: C
Available Work Time/Period 86400 Seconds

Customer Demand/Period 20477 Units Takt Time 4.2 Seconds/Unit

Prepared by johnny.fleming 11/14/2019 Page 3

 Planned Cycle Time Calculation =
F
Enter the following information: C
Takt Time 4.2 Seconds/Unit

OEE 73.0% Planned Cycle Time 3.1 Seconds/Unit

0%
Process Cycle Time 3 Seconds/Unit OEE Adjusted Process Cycle Time 4.1 Seconds/Unit

Notes:

Prepared by Johnny M. Fleming 11/14/2019 Page 4

Overall Equipment Effectiveness Calculation =
F
Enter the following information: C
Available Rate

Total Available Time 8 Hours 480

Planned Downtime
Breaks 15 Minutes
Shift Meeting 5 Minutes
PM / 5S 5 Minutes
TBD Minutes
0.4 Hours Scheduled Uptime 7.6 Hours 455 25

Downtime Losses
Changeovers 60 Minutes
Breakdowns 12 Minutes
Lack of Components 0 Minutes
TBD Minutes
1.2 Hours Available Rate 84.2% 72

Performance Rate

Actual Uptime 6.4 Hours Missing In Action 53 Minutes

Process Cycle Time 60 Seconds Missing In Action 53 Parts Actual Good Uptime
315
Total # Of Parts Produced 330 Performance Rate 86.2%

Quality Rate

Total # Of Parts Produced 330 Defective Cycle Time 15 Minutes

Total Defective Parts 15 Quality Rate 95.5% OEE 69.2%

Prepared by johnny.fleming 11/14/2019 Page 5

Prepared by johnny.fleming 11/14/2019 Page 6
Every Part Every Interval Calculation =

Enter the following information:

Part Numbers Assigned 15 Part Numbers

Available Time 1440 Minutes/Day
Daily Demand 20477 Units/Day
Planned Run Time 1024 Minutes/Day
Number Of Shifts 3 Shifts/Day
OEE Losses 181 Minutes/Day
Shift Duration 480 Minutes/Shift
Available C/O Time 235 Minutes/Day
Changeover Time 16 Minutes/Changeover
Additional Changeover Capacity 15 Changeovers/Day
Cycle Time 3 Seconds/Unit

OEE/Reliability 85% Every Part Every 1 Day

Prepared by johnny.fleming 11/14/2019 Page 7

 F
C

Changeovers/Day

Prepared by johnny.fleming 11/14/2019 Page 8

Machine Capacity Analysis =
F
Enter the following information:
C
Planned Days/Year 249 Theoretical Theoretical Machine
Machine Capacity Capacity Less OEE
Planned Days/Month 20.75
7171200 Units/Year 6238944 Units/Year
Planned Hours/Shift 8 Hours
597600 Units/Month 519912 Units/Month
Number of Shifts 3 Shifts
28800 Units/Day 25056 Units/Day
Machine Cycle Time 3 Seconds
9600 Units/Shift 8352 Units/Shift
Machine OEE (Goal) 87%
1200.0 Units/Hr 1044.0 Units/Hr

20.0 Units/Min 17.4 Units/Min

Prepared by johnny.fleming 11/14/2019 Page 9

 Machine Capacity Chart
4
Time (Seconds)

3.5

2.5

1.5

0.5

0
PA OH0 FA
Unload / Start Time Machine C/T Takt Time Planned C/T MEMCT

Prepared by johnny.fleming 11/14/2019 Page 10

hine Capacity Chart

FA
/T Takt Time Planned C/T MEMCT

Prepared by johnny.fleming 11/14/2019 Page 11

 Lot Formation Capacity Check =

Enter the following information:

Demand 18500 Units/Day Available Time

Number Of Shifts 3 Shifts/Day Planned Run Time

Planned Hours/Shift 8 Hours OEE Losses

Process Cycle Time 2.64 Seconds/Unit Available C/O Time

OEE/Reliability 70.5% Changeover Capacity

Avg. Changeover Time 10 Minutes

Lot (Kanban ) Size 121 Units Lot Formation Size

Lot Formation Size 7 Lots Projected Changeovers

Notes:
 F
C
1440 Minutes/Day

814 Minutes/Day

341 Minutes/Day

285 Minutes/Day

28.5 /Day (Max)

847 Units

21.8 /Day
 Single Stack Chart =
F
Enter the following information: C
Work Element Description Time(sec) Station Description
Element 1 5
Element 2 5
Element 3 5
Element 4 5
Element 5 5
Element 6 5
Element 7 5
Element 8 5
Element 9 5
Element 10 5
Element 11 5
Element 12 5
Element 13 5
Element 14 5
Element 15 5
Element 16 5
Element 17 5
Element 18 5
Element 19 5
Element 20 5
Element 21 5
Element 22 5
Element 23 5
Element 24 5
Element 25 5

Total Work Content 125 Seconds

Notes:
 Single Stack Chart

130
125
120
115 Element 25 Element 24
110
105 Element 23 Element 22
Time (Seconds)

100
Element 21 Element 20
95
90 Element 19 Element 18
85
80 Element 17 Element 16

75
Element 15 Element 14
70
65 Element 13 Element 12
60
55 Element 11 Element 10

50
Element 9 Element 8
45
40 Element 7 Element 6
35
30 Element 5 Element 4
25
Element 3 Element 2
20
15
Element 1
10
5
0
 Operator Balance Chart
140 140
Time (Seconds)

130
120 120
110
100 100
90
80 80
70
60 60
50
40 40
30
20 20
10
0 0
Operator 1 Operator 2 Operator 3 Operator 4 Operator 5 Operator 6
Lowest Repeatable Cycle Average Cycle Takt Planned Cycle Time Variation
Minimum Operator Cycle

Prepared by Johnny M. Fleming 11/14/2019 Page 16

 80 80 80 80 80

75 Wait 75 Wait 75 Wait 75 Wait 75 Wait

70 Walk 70 Walk 70 Walk 70 Walk 70 Walk

65 Element 10 65 Element 10 65 Element 10 65 Element 10 65 Element 10

60 Element 9 60 Element 9
60 Element 9 60 Element 9
60 Element 9

55 55 55 55 55
Element 8 Element 8 Element 8 Element 8 Element 8

50 50 50 50 50
Element 7 Element 7 Element 7 Element 7 Element 7

45 45 45 45 45
Element 6 Element 6 Element 6 Element 6 Element 6
40 40 40 40 40
Element 5 Element 5 Element 5 Element 5 Element 5
35 35 35 35 35
Element 4 Element 4 Element 4 Element 4 Element 4
30 30 30 30 30
Element 3 Element 3 Element 3 Element 3 Element 3
25 25 25 25 25
Element 2 Element 2 Element 2 Element 2 Element 2
20 20 20 20 20
Element 1 Element 1 Element 1 Element 1 Element 1
15 15 15 15 15

10 Planned Cycle Time Planned Cycle Time 10 Planned Cycle Time Planned Cycle Time Planned Cycle Time
10 10 10

5 Takt 5 Takt 5 Takt 5 Takt 5 Takt

0 0 0 0 0
Operator #1 Operator #2 Operator #3 Operator #4 Operator #5
Note: Assure the Y-axis (Seconds) for each chart are scaled the same.

Prepared by Johnny M. Fleming 11/14/2019 Page 17

 Minimum Manning Calculation =
F
Enter the following information: C
Total Work Content 30 Seconds/Unit

Takt Time 23.9 Seconds/Unit Number of Operators 1.3

Planned Cycle Time 19.1 Seconds/Unit Number of Operators 1.6

Process Cycle Time 18 Seconds/Unit Number of Operators 1.7

Notes:

Prepared by johnny.fleming 11/14/2019 Page 18

Value Added Ratio Calculation =
F
Enter the following information: C
Value Added Time 2.75 Seconds

Non-Value Added Time 14.2 Seconds Value Added Ratio 16%

Prepared by johnny.fleming 11/14/2019 Page 19

 Kanban Calculation =
F
Enter the following information: C
Average Demand 64 Units/Day

Safety Factor 20%

Kanban Cycle Time

*1 21600 Minutes
*2 Minutes
*3 0 Minutes
*4 Minutes Number of Kanban
*5 0 Minutes
*6 0 Minutes
15.0 Days Container Full 6

Kanban Lot Size 200 Units Container Empty 7

Note: Must at least have two Kanban

*1 Kanban waiting time in scheduling post

*2 Lot process time (internal setup time + run time + in-process waiting time)
*3 Container conveyance time to downstream buffer/supermarket
*4 Kanban waiting time at receiving post
*5 Kanban return time to scheduling post
*6 Miscellaneous

Prepared by johnny.fleming 11/14/2019 Page 20

Pitch Calculation =
F
Enter the following information: C
Takt Time 4.2 Seconds/Unit

Pack-Out Quantity 20 Units Pitch 1.400 Minutes

Available Work Time 1440 Minutes/Period Pitch Interval 1029 Pitches/Period

Prepared by johnny.fleming 11/14/2019 Page 21

Average Cycle Time Calculation =
F
Enter the following information: C
Model % Total Cycle Time

A 35% 7.1 Seconds/Unit

B 16% 24.2 Seconds/Unit

C 49% 14.2 Seconds/Unit

D 0% 0 Seconds/Unit Average Cycle Time 13.32 Seconds/Unit

100%

Prepared by johnny.fleming 11/14/2019 Page 22

First Pass Yield Calculation =
F
Enter the following information: C
Total # Of Parts Produced 1126152 Defect Rate 1%

Total Defective Parts 12100 FPY 99%

Prepared by johnny.fleming 11/14/2019 Page 23

Productivity Calculation =
F
Enter the following information: C
# Of Good Parts 92

Working Hours 7.5 Productivity 0.326 Man Hrs./pcs

# Of Operators 4 Productivity 32.609 Man Hrs./100pcs

Prepared by johnny.fleming 11/14/2019 Page 24

 Inventory Turns Calculation =
F
Enter the following information: C
Cost Of Goods Sold (Annual) $30,000,000

Average Value Of Inventories (During The Year) $4,000,000 Inventory Turns 8

Notes:
 Standard Work In Process Calculation =
F
Enter the following information: C
Takt Time 40.0 Seconds/Unit 3.0 Units of Inventory

Planned Cycle Time 30.0 Seconds/Unit 4.0 Units of Inventory

0%
Process Lead Time 120.0 Seconds/Unit

Notes:

Prepared by Johnny M. Fleming 11/14/2019 Page 26

 Motion Economy Chart =
F
C
Category Score Time to Retrieve Score Remarks

Tools 4 180 seconds or more 1 must leave work area and search
Fixtures 1 60 seconds or less 2 must leave immediate work area
Parts & materials 3 20 seconds or less 3 within work area / must search or choose
Supplies 2 7 seconds or less 4 within work station / one step away
Power Tools 2 2 seconds or less 5 within range of natural motion / strike zone

Tools
5

Power Tools 3 Fixtures

1

Supplies Parts & materials

 Tools
5

Power Tools 3 Fixtures

1

Supplies Parts & materials