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Ch03 Work Flow

The starting batch size required is 1857 units. The yield of the 10-operation sequence is 53.9%

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13 views39 pages

Ch03 Work Flow

The starting batch size required is 1857 units. The yield of the 10-operation sequence is 53.9%

Uploaded by

faisalf155m
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Work Flow and Batch Processing

Sections:
1. Sequential Operations and Work Flow
Chapter 3 2. Batch Processing
3. Defects in Sequential Operations and
Batch Processing
4. Work Cells
Some Definitions
 Sequential operations – series of separate
processing steps that are performed on each
work unit
 Work flow – physical movement of work units
through the sequence of unit operations
 Batch processing – processing of work units in
finite quantities or amounts
Sequential Operations in Industry
 Manufacturing
 Assembly
 Construction
 Mortgage applications
 Medical services
 Education
 Transportation
Work Flow Patterns
 Pure sequential – all work units follow the
same exact sequence of operations and
workstations
 Work flow is identical for all work units
 Mixed sequential – different work units are
processed through different operations
 Different work flows for different types of
work units
Work Flow Patterns
Network diagrams representing (a) pure sequential
work flow and (b) mixed sequential work flow
Moves in Sequential Work Flow
 In-sequence move – forward transport to
operation immediately downstream
 Bypassing move – forward transport to an
operation beyond the neighboring station
 Backflow – transport in a backward direction
 Repeat operation – operation is repeated at the
same workstation
Four Types of Work Movement
From-To Chart
 Indicates any of several possible quantitative
relationships among operations in a multi-
station work system
 Possible variables in a from-to chart:
 Quantities moving between operations
 Flow rates of materials
 Distances between work stations
From-To Chart

To operation j
1 2 3 4 5
1 - 40 15
2 - 30
From operation i 3 10 - 20
4 25 50
5 -
Network Diagram
Network diagram showing same data as in
previous From-To Chart
Bottlenecks in Sequential Operations
 Bottleneck = slowest operation in the sequence
 The bottleneck operation limits the production
rate for the entire sequence
 Terminology:
 Blocking – production rate(s) of one or more
upstream operations are limited by the rate
of a downstream operation
 Starving - production rate(s) of one or more
downstream operations are limited by the
rate of a upstream operation
Batch Processing
 Batch processing - processing of work units in
finite quantities or amounts
 Work units can be materials, products,
information, or people
 Batch processing is common in production,
logistics, and service operations
Examples of Batch Processing
Batch production in manufacturing
Passenger air travel
Cargo transport
Book publishing
Entertainment
Payroll checks
Class action lawsuits
Laundry
Grading of student papers
Types of Batch Processing
 Sequential batch processing – members of
the batch are processed one after the other
 Simultaneous batch processing – members
of the batch are all processed at the same
time
Examples of Batch Processing
Sequential Simultaneous
Production machining Chemical batch
Batch assembly processes
Book printing Heat treating of multiple
parts
Payroll checks
Passenger air travel
Grading of student
papers Cargo transport
Laundry
Batch Production

Alternating cycles of setup and production run


experienced by a work system engaged in batch
production
Why Batch Processing is Important
 Work unit differences – different types of work
units must be processed separately
 Learning curve effect – cycle time per work unit
decreases as batch quantity Q increases
(apples only to sequential batch production)
 Equipment limitations – limits on the quantities
that can be processed
 Material limitations – the material must be
processed as a unit (e.g., processing of
integrated circuits on a silicon wafer)
Disadvantages of Batch Processing
 Changeovers between batches represent lost
productive time
 Setup changeovers in batch production
 Airplanes at a terminal unloading and
loading passengers
 Work-in-process – multiple batches competing
for the same equipment
 Queues of work units form in front of each
workstation, resulting in large inventories of
partially processed units
Economic Order Quantity Model
Inventory level over time in a typical make-to-stock
situation
Economic Order Quantity Model
Total annual inventory cost TIC
ChQ Csu Da
TIC = +
2 Q

where Ch = inventory carrying cost, Q = batch


quantity, Csu = setup or ordering cost, and Da =
annual demand
Economic Order Quantity Model
 From the total inventory cost equation can be
derived the batch size that minimizes the sum
of inventory carrying costs and setup costs

2 Da Csu
Q = EOQ =
Ch
Defects in Unit Operations
 Input/output relationship for a unit operation in
batch processing
Q = Qo(1 – q)
where Q = quantity produced, pc; Qo = original
starting quantity, pc; q = fraction defect rate
D = Qo q
where D = number of defects
Defects in Unit Operations

Processing of Qo starting units to yield Q good


products and D defects
Defects in Sequential Operations and
Batch Processing
 Input/output relationship in a sequence of n unit
operations
Qf = Qo(1 – q1)(1 – q2) . . (1 – qn)
where Qf = final quantity at the conclusion of
the sequence
 Defects Df = Qo – Qf Qf
 Yield for the sequence Y = Q
o
Sequential Operations
Compounding effect of fraction defect rate at
each unit operation in a sequence of operations
Work Cells
Work cell - a group of workstations dedicated to
the processing of a range of work units within a
given type
 Part family – the range of work units that are
processed
 Members of the part family are similar but
not identical
 Mixed sequential work flow system
 Work cells and part families are associated
with group technology
Group Technology
An approach to manufacturing in which similar
parts are identified and grouped together to
take advantage of their similarities in design
and production
 Work units are processed individually and
continuously, without the need for time-
consuming changeovers between part types
 Avoids disadvantages of batch processing
Work Cell Layouts
 In-line – straight line flow of work units
 U-shaped – shape of work flow is “U”
 Similar to in-line except for shape
 Better communication among workers
 Loop – continuous flow of work units around a
loop layout
 Rectangular - similar to loop layout
In-Line Work Cell
U-Shaped with Manual Handling
U-Shaped with Mechanized Handling
Work Cell with Loop Layout
Work Cell with Rectangular Layout
Worker Teams
 Group of workers who work as a team to
achieve common objectives:
 Meet the production or service schedule
 Achieve high quality in the goods and
services provided by the cell
 Make the operation of the cell as efficient as
possible
Success Factors for Worker Teams
 Teamwork – the collective skills and efforts of
the team members exceed the sum of their
individual skills and efforts
 Cross-training – workers become trained in
more than one job in the cell
 Allows for job rotations to increase work
variety and job satisfaction
 Mitigate problems of absences
Example
The yearly demand for a cake = 150,000 pc.
Average cost per piece = $20; holding cost = 25%;
changeover (setup) time for the presses = 5 hours;
and cost of downtime for changing over = $200/hr.
A.Calculate the economic batch size
B.The total annual inventory cost .
Solution:
(a)Csu = 200(5) = $1000, Ch = 0.25(20) = $5.00

2(150 ,000) (1000)


EOQ = = 7746 pc
5.00

(b) TIC = (7746 /2)(5.00) + (150,000/7746)(1,000) =


19,365 + 19,365 = $38,730
Example
A total of 1000 foot ball must be made by a
sequence of 10 workers, each has fraction defect
rate of 6%.
(a) How many units must be in the starting batch
in order to produce this required quantity?
(b) What is the yield of the operation sequence?
(a) Qf = 1000 = Qo(1 – 0.06)10 = Qo(0.94)10 = Qo(0.5386)
Qo = 1000/0.5386 = 1857 pc

(b) Y = 0.5386 = 53.9%

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