Process Analysis Part 3 - Notetaking-1
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Northeastern University *
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Course
2301
Subject
Industrial Engineering
Date
Feb 20, 2024
Type
pptx
Pages
16
Uploaded by amanda01001
Welcome back to Operations Processes
Process Analysis – part 3
(minimum throughput, examples, practice)
Brought to you by:
Dr. Julia A. Kalish
1
Process Analysis
Reminders & Updates:
•
No Class on Monday, Sept 4
th
!!!!
•
HW 2 is posted & Due Sunday by midnight
•
A help & hints document has been posted to assist with HW 2
2
Process Analysis
Example 2.7
CT for Stage 1:
CT for Stage 2:
Bottleneck:
Process CT :
Process Capacity:
Min TPT:
= 3.75/ unit
= 4 min/unit
Stage 2
= 4 min/unit (based on the bottleneck)
= ¼ unit/ min 15 unit/ hour
= 6+4 = 10 (pick the faster in parallel)
Stage 1
Stage 2
M3
4 min
M2
6 min
M1
10 min
Capacity of M1: 6 [units/hr]
((1/10) * 60))
Capacity of M2: 10 [units/hr]
((1/6) * 60))
Total for Stage 1: 16 [units/hr]
(6 + 10 ) Design parameters
3
Process Analysis
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4
M1
M2
M3
Buffer
(2 min)
6 10 14 18 22 26 30 34 38 42
Idle time ignored in WIP calculations
5
4
4
5
6
6
6
2
1
1
2
3
3
3
8
7
7
8
9
9
9
Schedule: Start a job every 12 minutes on M1 (0, 12, 24, ..). Start a job every 6 minutes on M2 (0, 6, 12, ..).
Process Analysis
Example 2.7 – How much WIP?
CT:
Average TPT:
WIP M1:
M2:
Buffer:
M3:
Total
:
4 [min/unit]
_1/3*(10+14+12)=12____________[min]
____10/12=5/6 units_
(10 min of work + 2 idle mins)
___1 units_____
___2/12 units_______________
(2 min of buffer + 10 min empty)
___3 units_________
__________________________________
M1
M2
M3
Buffer
6 10 14 18 22 26 30 34 38 42
Idle time ignored in WIP calculations
5
4
4
5
6
6
6
2
1
1
2
3
3
3
8
7
7
8
9
9
9
Little’s Formula
WIP = TPT / CT [
Q
] = [
T
] / [
T /
Q ].
3 = 12 / 4 [units] = [min] / [min / unit]
Stage 1
Stage 2
M3
4 min
M2
6 min
M1
10 min
5
Run Time Parameters
Process Analysis
Assembly Operations Example 2.13: What is the Process Capacity?
M1
9 min
AA
BB
M2
5 min
X1
3 min
Y1
5 min
P1
4 min
R1
16 min
R2
18 min
R3
15 min
Stage 1
Stage 2
Stage 4
Stage 3
Stage 5
St
Cycle Time
1
2
3
4
5
3.21 [min/unit] 3 [min/unit]
5 [min/unit]
4 [min/unit]
5.41 [min/unit]
Bottleneck?
AA
BB
Process Capacity = 1/5.41 [u/min] * 60 [min/h]
11 units / hour
WIP cannot be determined, different product after assembly !
6
Process Analysis
But wait, there’s more
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Assembly Operations Example 2.13 – continued M1
9 min
AA
BB
M2
5 min
X1
3 min
Y1
5 min
P1
4 min
R1
16 min
R2
18 min
R3
15 min
Stage 1
Stage 2
Stage 4
Stage 3
Stage 5
From Stage 1, you can get at the end of 5 minutes
From Stages 2 and 3, you can get at the end of 8 minutes
Both are required for the assembly. So you can start assembly after 8 minutes. Add 4 minutes on P1 then 15 minutes on R3.
= 8 + 4 + 15 = ___27_ min
AA
BB
7
Process Analysis
What is the Minimum TPT ?
8
Emily, Anna, Maddie, Sarah, and Katie are cousins who all live in Willkie. Maddie has landed 3 last-minute tickets to see Taylor Swift in concert TONIGHT. She doesn’t have a car & has offered the other 2 tickets to whomever can get her to the concert as soon as possible. Emily & Anna share a room and a car. Whichever of them can be ready first & grab the keys will get to go, however because the car was last driven by their cousin Katie they aren’t sure where it is parked & Katie is holding this information hostage as leverage to get to go to the concert. Sarah is another cousin who, for no particular reason, always has a can of gas in case of emergency. When Katie borrowed the car she let it completely run out of gas so she needs Sarah’s can of gas if they are going to get to the concert. It takes Sarah 4 min to locate the gas and walk next door to give it to Katie, after receiving the gas Katie takes 5 min to get ready, then heads toward the parking lot. She texts Emily (who has the keys) to tell her where the car is. It has taken Emily 10 min to get to the parking lot so Katie had to stand outside the car & wait for Emily to arrive. Once the key, the car, and the gas are all together the 2 girls can head toward the back of Willkie to pick up Maddie (who has the tickets). They have to wait for 5 min for Maddie to come out & hop into the car. When they get to the concert there are 3 security lines which seem to be moving at different rates. They hop into the fastest line and make it through security and into their seats in just 2 min.
How long in total did it take to get into their seats?
Another Way to Look at It
Process Analysis
How fast can 3 cousins get to a concert?
Example 2.14 Emily
10 min
s1
s2
Anna
11 min
Sarah
4 min
Katie
5 min
Maddie
5 min
Dude 1 4 min
Chic 2
3 min
Dude 3
2 min
Stage 5
= 10 + 5 + 2 = __17__min
9
s3
s4
What is the fastest time to get into the seats?
What could you consider the parking lot? Process Analysis
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In-class Exercise – Care Packages
•
Listen to case details
•
Get into groups of 3 - 4
•
Designate a facilitator
•
Re-Read the handout as needed
•
Work through the case by answering/doing the 13 steps.
•
Be ready to share your final recommendation.
Process Analysis
10
You have a friend who is starting a side-hustle to create care packages for homesick freshmen. The packages can be ordered online by loved ones and will be personally delivered to the freshman’s dorm rooms along with an optional hug. A short video will be taken as the package is handed to the freshman. It will provide proof of delivery and be a nice keepsake for the sender. Your friend is super jazzed about this idea but is a liberal arts major, so they don’t know where to begin to make this all happen. They have asked you and your team to be consultants to help launch this small business. Process Analysis
11
Here's what your friend has puzzled out so far:
•
* They will be working on an old beer-pong table that can seat up to 6 people.
•
* The items that will be included in the basket are: a Mother Bears gift card, red & white rally beads, a KIND bar, a travel-sized LCR game, 2 bags of Frito-
Lay chips, IU-themed playing cards, Burt’s Bees lip balm, and a mug cake. •
* All items are arriving in bulk & must be unboxed and unpackaged in preparation for repackaging into the care packages.
•
* Ultimately the packages will be wrapped in cellophane in preparation for delivery.
•
* A delivery label must be attached to each package. Process Analysis
12
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Your friend is pretty sure they have missed some details, but they are counting on you to connect the dots. •
Based on a quick Google search they believe they will be able to sell about 50 baskets & they already have 3 friends willing to help out for up to 4 hours. They have a few more friends that could probably be bribed with Starbucks gift cards to help for a few more hours as needed. Your friend was so excited about this idea that they went ahead and ordered all the items & the delivered boxes are now piled up in their apartment. As they get orders, they want to be able to get them out the door & to the freshmen as quickly as humanly possible. They only have this weekend to get it together before the website goes live and orders (hopefully) start to pour in.
Process Analysis
13
Complete the 13 steps below to help your friend. 1)Determine the most practical process type (make to order, make to stock, hybrid).
2)Outline the pros & cons of the process type you are using.
3)List the 3 steps that should be taken to begin a process design analysis.
4)List what tasks are necessary to create the care packages.
5)Combine the tasks into stages.
6)Determine how long each stage will take (use your best judgment).
7)Create a table of tasks, precedence, and times.
Process Analysis
14
Complete the 13 steps below to help your friend. 8) Sketch out a precedence diagram. 9) Sketch out at least 3 possible process arrangements.
10)Determine which arrangement has the best labor productivity. 11)Attempt to improve the best of the 3 arrangements by adding one person to work in parallel at the bottleneck stage.
12)Recalculate your labor productivity once you’ve added the additional person. Then determine if the process improved, stayed the same, or decreased.
13)Make a final recommendation to your friend on what process arrangement should be used to create the care packages. Process Analysis
15
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Process Analysis
16