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    Vut Calculator

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    This document contains the output of a VUT calculator simulation that analyzed a 5 station production line. Station 3 was identified as the bottleneck. The summary lists 7 potential improvement options to increase throughput and reduce cycle times and work in progress for the system. The options focus on increasing capacity and reducing variability at the bottleneck station 3 as well as nearby non-bottleneck stations 2 and 4. Batch size reductions are also suggested as they contribute significantly to delays. The effectiveness of improvements is estimated to follow the order of reducing batching, then increasing bottleneck capacity, reducing bottleneck variability, and so on.

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    Vut Calculator

    Uploaded by

    B'MAZ
    884 views3 pages
    This document contains the output of a VUT calculator simulation that analyzed a 5 station production line. Station 3 was identified as the bottleneck. The summary lists 7 potential improvement options to increase throughput and reduce cycle times and work in progress for the system. The options focus on increasing capacity and reducing variability at the bottleneck station 3 as well as nearby non-bottleneck stations 2 and 4. Batch size reductions are also suggested as they contribute significantly to delays. The effectiveness of improvements is estimated to follow the order of reducing batching, then increasing bottleneck capacity, reducing bottleneck variability, and so on.

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    This document contains the output of a VUT calculator simulation that analyzed a 5 station production line. Station 3 was identified as the bottleneck. The summary lists 7 potential improvement options to increase throughput and reduce cycle times and work in progress for the system. The options focus on increasing capacity and reducing variability at the bottleneck station 3 as well as nearby non-bottleneck stations 2 and 4. Batch size reductions are also suggested as they contribute significantly to delays. The effectiveness of improvements is estimated to follow the order of reducing batching, then increasing bottleneck capacity, reducing bottleneck variability, and so on.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    884 views3 pages

    Vut Calculator

    Uploaded by

    B'MAZ
    This document contains the output of a VUT calculator simulation that analyzed a 5 station production line. Station 3 was identified as the bottleneck. The summary lists 7 potential improvement options to increase throughput and reduce cycle times and work in progress for the system. The options focus on increasing capacity and reducing variability at the bottleneck station 3 as well as nearby non-bottleneck stations 2 and 4. Batch size reductions are also suggested as they contribute significantly to delays. The effectiveness of improvements is estimated to follow the order of reducing batching, then increasing bottleneck capacity, reducing bottleneck variability, and so on.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 3

    VUT Calculator

    Wallace J. Hopp, Mark L. Spearman, 1999


    MEASURE:
    Arrival Rate (parts/hr)

    ra

    1
    10.000

    2
    9.800

    3
    9.310

    4
    8.845

    5
    7.960

    Arrival CV
    Natural Process Time (hr)

    ca 2
    t0

    1.000
    0.090

    0.181
    0.090

    0.031
    0.095

    0.061
    0.090

    0.035
    0.090

    Natural Process SCV


    Number of Machines
    MTTF (hr)
    MTTR (hr)
    Availability
    Effective Process Time (failures only)

    c0 2
    m
    mf
    mr
    A
    te'

    0.500
    1
    200
    2
    0.990
    0.091

    0.500
    1
    200
    2
    0.990
    0.091

    0.500
    1
    200
    8
    0.962
    0.099

    0.500
    1
    200
    4
    0.980
    0.092

    0.500
    1
    200
    4
    0.980
    0.092

    Eff Process SCV (failures only)


    Batch Size
    Setup Time (hr)

    ce2'
    k
    ts

    0.936
    100
    0.000

    0.936
    100
    0.500

    6.729
    100
    0.500

    2.209
    100
    0.000

    2.209
    100
    0.000

    cs2
    ra/k
    te = kt0/A+ts

    1.000
    0.100
    9.090

    1.000
    0.098
    9.590

    1.000
    0.093
    10.380

    1.000
    0.088
    9.180

    1.000
    0.080
    9.180

    0.773

    1.023

    6.818

    1.861

    1.861

    0.009
    0.909

    0.011
    0.940

    0.063
    0.966

    0.022
    0.812

    0.022
    0.731

    cd 2
    y
    ra*y

    0.181
    0.980
    9.800

    0.031
    0.950
    9.310

    0.061
    0.950
    8.845

    0.035
    0.900
    7.960

    0.028
    0.950
    7.562

    0.198
    0.909
    9.800
    45.825
    54.915
    54.915
    458.249
    549.149
    549.149

    0.079
    0.940
    9.310
    14.421
    24.011
    78.925
    141.321
    235.303
    784.452

    0.108
    0.966
    8.845
    14.065
    24.445
    103.371
    130.948
    227.586
    1012.038

    0.132
    0.812
    7.960
    1.649
    10.829
    114.200
    14.587
    95.780
    1107.818

    0.077
    0.731
    7.562
    0.716
    9.896
    124.096
    5.700
    78.773
    1186.591

    Setup Time SCV


    Arrival Rate of Batches
    Eff Batch Process Time (failures+setups)
    Eff Batch Process Time Var (failures+setups)
    Eff Process SCV (failures+setups)
    Utilization
    Departure SCV
    Yield
    Final Departure Rate
    Final Departure SCV
    Utilization
    Throughput
    Queue Time (hr)
    Cycle Time (hr)
    Cumulative Cycle Time (hr)
    WIP in Queue (jobs)
    WIP (jobs)
    Cumulative WIP (jobs)

    STATION:

    k*s02/A2+ 2mr(1-A)kt0/A+ss2
    ce2

    ycd2+(1-y)
    u
    TH
    CTq
    CTq+te
    Si(CTq(i)+te(i))
    raCTq
    raCT
    Si(ra(i)CT(i))

    Improvement Options:
    1) Station 3 is the bottleneck. Changes here will be most valuable.
    2) We could increase capacity at bottleneck by:
    - increasing MTTF to 400
    - decreasing MTTR to 4
    - reducing t_0 to 0.09
    - eliminating setups
    - increasing yield to 100%
    - add a second machine at station 3
    3) We could reduce variability at bottleneck by:
    - cutting both MTTF and MTTR in half
    - reducing c_0 to 0
    - halving batch size and setup times
    - reduce setup time CV to zero
    4) We could increase capacity at nonbottleneck by:
    - speeding up station 2 by making t_0 = 0.85
    - increasing MTTF at station 2 to 400
    - decreasing MTTR at station 2 to 1
    - eliminating setups at station 2
    - increasing yield to 100% at station 2
    5) We could decrease variability at nonbottleneck by:
    - cutting both MTTF and MTTR in half at station 2
    - reducing c_0 to 0 at station 2
    - halving batch size and setup times at station 2
    6) Note that if we do similar changes to those in (5) to station 4,
    the effect will be much less, since this is downstream
    from the bottleneck.
    7) A big portion of delay in this example is due to batching
    - reduce setup times in half and halve all batch sizes

    TH
    7.56

    CT
    124.10

    WIP
    1240.96

    7.56
    7.56
    7.56
    7.56
    7.96
    7.56

    115.56
    113.86
    121.43
    115.12
    124.81
    111.19

    1155.60
    1138.64
    1148.71
    1151.15
    1248.14
    1065.84

    7.56
    7.56
    7.56
    7.56

    119.25
    123.32
    117.79
    123.70

    1192.53
    1233.19
    1177.90
    1236.98

    7.56
    7.56
    7.56
    7.56

    118.67
    122.77
    122.57
    118.34
    -

    1186.74
    1227.68
    1225.69
    1183.43
    -

    7.56
    7.56
    7.56

    123.69
    123.16
    113.53

    1236.89
    1231.61
    1135.25

    7.56

    69.17

    691.71

    Conclusion: improvements can be roughly ordered in terms of effectiveness as:


    0) batching reductions (via setup time reduction) where batching is significant
    1) capacity improvements at bottleneck
    2) variability reductions at bottleneck
    3) capacity improvements (immediately) upstream from bottleneck
    4) variability reductions (immediately) upstream from bottleneck
    5) capacity/variability improvements downstream from bottleneck

    Note - unless we reduce release rate, TH goes up due


    to yield, which causes utilization and CT,WIP to go up too.

    Note - unless we reduce release rate, the increased yield at


    station 2 causes station 3 to become overloaded.

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