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WIP and Throughput Time

The document discusses work in progress (WIP) and manufacturing throughput time. It defines WIP as partially completed goods still in production and throughput time as the total time it takes a product to move through manufacturing from start to finish. Reducing WIP and throughput time provides benefits like smoother material flow, lower inventory levels, and the ability to generate revenue from products more quickly. Formulas are provided for calculating WIP and throughput time. Techniques for reducing them include line balancing, smaller batch sizes, and eliminating bottlenecks.

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Nitta Mallik
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194 views

WIP and Throughput Time

The document discusses work in progress (WIP) and manufacturing throughput time. It defines WIP as partially completed goods still in production and throughput time as the total time it takes a product to move through manufacturing from start to finish. Reducing WIP and throughput time provides benefits like smoother material flow, lower inventory levels, and the ability to generate revenue from products more quickly. Formulas are provided for calculating WIP and throughput time. Techniques for reducing them include line balancing, smaller batch sizes, and eliminating bottlenecks.

Uploaded by

Nitta Mallik
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Seminar

on
WIP & Throughput
Time
Contents:

 What is WIP
 What is the technique of Reducing WIP
 Root cause of WIP
 What is throughput time
 Formula for calculating WIP and Throughput Time
 Disadvantage of WIP
WIP can affect various areas in the manufacturing process,
IMBALANCE WIP like labor productivity and line efficiency. This is especially
important causes for bottlenecks in a manufacturing
operation.
 Work in progress or Work in Process (WIP) refers
to partially-completed goods that are still in the
production process. These items do not
include raw materials or finished goods. Work in
progress is usually comprised of the full amount
of raw materials required for a product, since
that is added at the beginning of production,
plus the cost of additional processing as each
unit progresses through the various
manufacturing steps.
 Forecasting and WIP Levels
 Setting production lay out with proper line balance
 Adding Machines and Improving Workforce

 Just in Time Production (JIT)

 Time Saving and Allocating the Right Operator

 Flow small bundle size in production line

 Make solution of bottleneck process by capacity sharing

 Develop methodologies of production line


 Manufacturing throughput time is the amount of time required
for a product to pass through a manufacturing process, thereby
being converted from raw materials into finished goods. The
concept also applies to the processing of raw materials into a
component or sub-assembly. The time required for something to
pass through a manufacturing process covers the entire period
from when it first enters manufacturing until it exits
manufacturing - which includes the following time intervals:
 Processing time. This is the time spent transforming raw
materials into finished goods.
 Inspection time. This is the time spent inspecting raw
materials, work-in-process, and finished goods, possibly at
multiple stages of the production process.
 Move time. This is the time required to move items into and out
of the manufacturing area, as well as between workstations
within the production area.
 Queue time. This is the time spent waiting prior to the
processing, inspection, and move activities.
What Are The Benefits Of Reducing Throughput Time?

1.Smoth flow of material.


2.Reduce WIP in line.
3.Can develop Kanban with Cutting and Finishing
4. Turn company’s investment into revenue more quickly

How Can We Reduce Throughput Time?

1.By Balancing line properly.


2.Reducing bundle size.
Comparison Between Traditional line &
pilot Line Throughput time.
Pilot line Throughput Time
Traditional line Throughput Time(min)
sewing(min)
481 103
481 107
481 101
481 89
481 101.7
481 93
481 86
481 83
Avg WIP : 2400 pcs Avg WIP : 350 pcs

1.If throughput time is less that means materials are making money
quickly. That means material waiting time are reducing and WIP &
inventory are decreasing .
Throughput = WIP level x Cycle
Time(SMV)

•lead time is the time between the initiation and delivery of a work item.
•cycle time is the time between two successive deliveries
•throughput is the rate at which items are passing through the system.
•WIP – Work in progress; the number of work items in the system. Work
that has been started, but not yet completed
1.Need more space to cover WIP
2.Increase wastes motion of operator to manage big bundle
3.Mistake bundle size because of different size of the line.
4.Unnecessary transportation of bundle back and fro in the line.
5.Effective combo packing to the next operation or order(required
color matching for packing bundle.
6.Working time increase and excess overtime to finish WIP(lack of
team concept).
7.Operator focus to finish the large WIP not focus on quality.
Quality at the source not focus, It increases alter%, reject%. its
totally waste.

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