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Process Analysis

This document defines key process analysis terms and concepts including process, cycle time, utilization, buffering, blocking, starving, productivity, and efficiency. It provides examples to illustrate these concepts for a sub shop process and other manufacturing processes. Key terms are defined as processes that transform inputs to outputs, cycle time is the average time between completing successive units, and utilization is the ratio of active time to available time for a resource. Buffering, blocking, and starving relate to internal storage between process stages. Productivity and efficiency compare actual outputs to standards or potential outputs. The examples walk through calculating metrics like maximum output, benefits of adding resources, and impacts of shifting times between stages.

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Kiran Vidhani
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Download as PDF, TXT or read online on Scribd
67 views

Process Analysis

This document defines key process analysis terms and concepts including process, cycle time, utilization, buffering, blocking, starving, productivity, and efficiency. It provides examples to illustrate these concepts for a sub shop process and other manufacturing processes. Key terms are defined as processes that transform inputs to outputs, cycle time is the average time between completing successive units, and utilization is the ratio of active time to available time for a resource. Buffering, blocking, and starving relate to internal storage between process stages. Productivity and efficiency compare actual outputs to standards or potential outputs. The examples walk through calculating metrics like maximum output, benefits of adding resources, and impacts of shifting times between stages.

Uploaded by

Kiran Vidhani
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Process Analysis
DR. NIRAV B. HALVADIA
ASSOCIATE PROFESSOR, SKIPS, AHMEDABAD
Process Analysis Terms 2

 Process: Is any part of an organization that takes inputs and


transforms them into outputs.
 Cycle Time: Is the average successive time between completions
of successive units.
 Utilization: Is the ratio of the time that a resource is actually
activated relative to the time that it is available for use.
Utilization 3

 Note that this car wash can handle 20 cars an


hour (3 minutes per car). If, in reality, only 10 cars
on average arrive in an hour, the utilization of this
facility is only 50 percent (10 cars per hour/20 cars
per hour).
 Utilization is the ratio of the time that a resource is
actually activated relative to the time that it is
available for use.
Cycle Time 4

 The cycle time of a repetitive process is the


average time between completions of successive
units.
 Suppose we have an automatic car wash that
can wash one car in 3 minutes. Assuming that
there are many cars waiting to be washed all the
time, the cycle time for the wash is then 3 minutes.
, i.e., a car comes out of the wash every 3
minutes. However, if, on average, only 10 cars
come in an hour, then the actual cycle time is 6
minutes (one car coming out every 6 minutes on
average), even though the fastest cycle time for
the car wash is 3 minutes. To be consistent, in this
text the term “cycle time” refers to the fastest
cycle time.
Buffering, Blocking, and 5

Starving
 A multiple-stage process may be
buffered internally. Buffering refers to a
storage area between stages where the
output of a stage is placed prior to being
used in a downstream stage. Buffering
allows the stages to operate
independently. If one stage feeds a
second stage with no intermediate
buffer, then the assumption is that the
two stages are directly linked. When a
process is designed this way, the most
common problems that can happen are
blocking and starving.
Productivity 6

 Productivity is the ratio of output to input.


Efficiency 7

 Efficiency is a ratio of the actual output of a


process relative to some standard.
 For example, consider a machine designed to
package cereal at a rate of 30 boxes per minute. If,
during a shift, the operators actually produce at a
rate of 36 boxes per minute, then the efficiency of
the machine is 120 percent (36/30).
Example 1 8

 Daffy Dave’s Sub Shop makes custom submarine


sandwiches to order. Dave is analyzing the processes at
the shop. The general low of the process is shown below.
A separate person works at each of the steps in the
process.
Example 1 9

 Daffy Dave wants to figure out the following for a


typical 8-hour work day.
a. What is the current maximum output of the
process?
b. If we add another person, where would we
add him or her and what is the benefit?
c. Is there a benefit if we can shift 1 minute from
Bun and Meat to Order Taking? Assume we do
not make the change in part b above.
d. Is there a benefit if we shift 1 minute of work
from Condiments to Bagging? Assume we do not
make the changes in parts b and c above.
Example 1
10
Example 1
11
Example 1 12
Example 2
13
Example:3

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Product-Process Matrix 15
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THE END

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