IND 400 Chapter Notes - Chapter 2: Takt Time, Pareto Analysis, Industrial Engineering
2 May 2018
School
Department
Course
Professor
CHAPTER 2:
SOURCES OF INFO FOR MANUFACTURING FACILITIES DESIGN
• info comes from other departments within the company
• The larger the company is, the less data are actually produced by the designer.
• Some companies have several sub-departments within manufacturing and industrial
engineering.
Examples:
1. The processes section would establish the routing and select the machine to be used.
2. The tool design section would design the fixtures and specify the specific
tools.
3. The time standards application section would set the time standards for each operation.
4. The quality department would specify inspection procedures and require space for tools and
people.
5. The safety department will want to review and input its requirements.
6. Inventory and production control department policies will affect the space needs as well as
the procedures.
There are three basic sources of information outside the manufacturing department:
1. Marketing
2. Product design
3. Management policy
Marketing department: - what the customers want and need / customer demands
Provides:
(1) Selling price – impacts #uints the company sells
(2) Volume (how many can we sell?) – related to how many the company wants to produce
per day --- impacts # machines/ ppl --- determine plant rate based on this (how fast
every machine and workstation needs to work to meet the goal
20% of customers buy 80% of the total production (pareto analysis)
Therefore, if a small group of customers say that they will buy 125,000 units that
represent 50 percent of annual sales, 250,000 units will be needed. If the plant
works 250 days a year (50 weeks times 5 days per week), then 1,000 units would be
needed every day.
(3) Seasonality (is it a summer, winter etc product?)
(4) Replacement parts that an older product may require
Determining Takt Time (Plant Rate) – R value
rate at which operations, processes, parts, components & so on must run to meet
the production goal.
find more resources at oneclass.com
find more resources at oneclass.com
• Things you need to know to calculate it:
Production goal
Time allotted for the production of these units ( ie. 2 8hour shifts)
Nonproductive time that takes away from production time (ie. Breaks)
General knowledge of overall plant efficiency as determined by unplanned
downtimes, inventory stock-outs, absenteeism… etc.
• Example of TAKT time calculation:
Need to produce and ship 1,000 units of product demand
In an 8-hour shift production time
30 for lunch, 10 for break, and 8 min for team meetings during each shift
unproductive time
plant is operating at 90 percent efficiency plant efficiency
Takt time = Ta ri i
Ta aiy a in minutes/ unit
1/ Takt time = #units/ min.
find more resources at oneclass.com
find more resources at oneclass.com
Calculating Scrap and Rework Rates
• Quality and production departments have historical data that indicate the
level of rework and scrap for each operation.
Considerations in TAKT time calculations:
scrap and rework rates
the need for spare or replacement parts
In the preceding example:
• the press operation produces 3% scrap
• Therefore, to end up with 1,000 finished wagon bodies, you must start with a larger
number so that after scrapping 3 percent, you will have 1000 good parts
Takt time used for calculating:
the number of machines and workstations
the conveyor speed
the number of employees required
• Production and inventory control is a manufacturing extension of the marketing
department, and will probably be your source of volume information.
• production and inventory control policies will have a big effect on your design.
Replacements require you to:
build extra inventory
have storage and shipping areas
increase your volume to account for replacement parts on a part-by-part basis
find more resources at oneclass.com
find more resources at oneclass.com
Document Summary
There are three basic sources of information outside the manufacturing department: marketing, product design, management policy. Marketing department: - what the customers want and need / customer demands. Provides: (1) selling price impacts #uints the company sells (2) volume (how many can we sell?) Related to how many the company wants to produce per day --- impacts # machines/ ppl --- determine plant rate based on this (how fast every machine and workstation needs to work to meet the goal. 20% of customers buy 80% of the total production (pareto analysis) Therefore, if a small group of customers say that they will buy 125,000 units that represent 50 percent of annual sales, 250,000 units will be needed. Determining takt time (plant rate) r value. Rate at which operations, processes, parts, components & so on must run to meet the production goal: things you need to know to calculate it:
