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Manufacturing Operation As A Single System. OPERATION. OUTPUT (PRODUCTS). INPUT (RAW MATERIALS). CONTROL. Information flow. Manufacturing Operation As A Single System. LITTLE`S law: TH=WIP/CT. OPERATION. THROUGPUT (Products/Time). WORK IN PROCESS (Units of RAW MATERIALS).

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Manufacturing Operation As A Single System

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Manufacturing Operation As A Single System

OPERATION

OUTPUT

(PRODUCTS)

INPUT

(RAW MATERIALS)

CONTROL

Information flow

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Manufacturing Operation As A Single System

LITTLE`S law: TH=WIP/CT

OPERATION

THROUGPUT

(Products/Time)

WORK IN PROCESS

(Units of RAW MATERIALS)

CYCLE TIME (Time)

CONTROL

Information flow

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Variability

Sources Of Variability In A Single Operation

Processing

Inputs

Machine Failures

Shut downs due to quality problems

Operator´s Off Times

Slow downs due to set ups

Scheduled maintenance

Tardy arrivals of materials

High Work In Process

Priorities

Recycles

Defective materials

Tardy arrivals

Incomplete lots

Wrong lots

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Wo

Parameters And Variability Interrelationships

WIP

TH

CT

Variability

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Parameters And Variability Interrelationships

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Most

Dependent

Operation

5

Dependency Phenomenon

2

Raw materials

End Products

1

3

4

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


VARIABILITY

DEPENDENCY

Variability And Dependency Phenomenona Affect:

THROUGHPUT (TH)

WORK IN PROCESS (WIP)

CYCLE TIME (CT)

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Bottleneck Effect

ri = Production rate (parts/unit time)

1

2

3

r2

r1

r3

r1 = min (r1,r2,r3) is the bottleneck

Even if W increases as infinite,

TH is maximum r1

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Bottleneck Effect

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Global Processing Time:To

ti = Production time (time per unit)

1

2

3

t1

t2

t3

Global Processing Time To

To = t1 + t2 + t3

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Critical Wip:Wo

To = Global Processing

Time

rb = bottleneck rate

Wo = (rb). To

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Best Performance Law

W/To, if W < Wo or W =Wo

rb, otherwise

To, if W < Wo or W =Wo

W/rb, otherwise

Thbest =

Ctbest =

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Worst Performance Law

THworst = { W/(Wo+W-1)}* rb

CTworst = To + (W-1)/rb

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Some Performance Tips

TH REMAINS EQUAL OR LESSER

AS WIP INCREMENTS

CT INCREMENTS

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Some Performance Tips

MANUFACTURING PLANNERS

MUST TO KNOWWo

IT MEANS THEY HAVE TO KNOWrb

BECAUSEWo = rb.To

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Some Performance Tips

WIP MUST BE A CONTROL

PARAMETER

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Some Performance Tips

1. TO CONTROL WIP INSTEAD OF TO CONTROL THROUGHPUT

2. TO CONTROL VARIABILITY

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Some Performance Tips

MRPSYSTEMS CONTROLTHROUGHPUTINSTEAD OF CONTROLLINGWIP

MRPIS A POWERFUL INFORMATION TOOL

SOMEMRPSYSTEMS TREAT TO CONTROLVARIABILITY

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Some Performance Tips

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Some Performance Tips

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


Animated Simulation Benefits

STUDENTS MAY OBSERVE AND ANALYZE MANUFACTURING PARAMETERS WHILE SIMULATION RUNS

STUDENTS MAY CONSTRUCT STEP BY STEP MORE COMPLEX SYSTEMS

STUDENTS LEARN FACTORY PHYSICS BY DOING SIMULATION

Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING"


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