Process Analysis

G P Kurien

Process Analysis
1. Process analysis utilizes some analytical mechanism to

understand the impact of

process design on output, cost or any other
performance metric
alternative process configurations on the chosen
performance metric
2. Design & Analysis of process begins with identification of
activities that constitute the process
time taken for each of the activity
nature of flow of materials/information in the process.
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Flow charting
1. A pictorial representation of all these information could

be developed using process flow charting.

Process flow charting employs a set of standard symbols and

graphical tools to represent all the information pertaining to
the process
3. The symbols used are
2.

A step in the Process

A resource (machine is utilised)
Transportation (Move)
Storage or Inventory

Decision

Start/ End :
Continuation Point

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Process Flow Chart for Shirt

Manufacturing

Stitching 1
Spreading cloth

Cutting

Stitching 2

Pressing &
Inspection

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Process Analysis
1. Throughput time: Throughput time (TPUT) is the

elapsed time from the first stage of the process to

the last stage of the process. It is also known as
lead time.
2. Cycle Time: Cycle time is the elapsed time between
two successive output from a process that is
continuously operating in a given period of time.
3. Bottleneck: That stage of the process that dictates
the output of a process is the bottleneck.
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Toy Manufacturing: Example

1.

A toy manufacturer receives crafted toys from local carpenters

and performs the final operations before stocking it for sale.
The process consists of five steps. The first step is to arrange a
set of four toys in a pallet. After this, the pallet moves to the
next station where the toys are pre-treated. This is to increase
the toys life. The next step is to send it to the spray painting
chamber, where it is painted as per the specifications. At
present there is only one spray painting machine. After
painting it is left in an open area for drying. The painting
process and the pre-treatment process are specialized so the
paint dries quickly. Finally the toys are inspected and packed.

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Toy Manufacturing
1.

2.
3.
4.

5.

(a)
(b)
(c)
(d)
(e)
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Step 1: Preparation of toys 8 minutes

Step 2: Pre-treatment 12 minutes
Step 3: Painting 20 minutes
Step 4: Drying 10 minutes
Step 5: Inspection and packing 5 minutes
Develop a process flow diagram for these steps and answer the
following.
What is the throughput time for this manufacturing process
Identify the bottleneck for this process?
What is the cycle time for this process?
What is the productive capacity of the process?
What are the assumptions behind this computation?

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Prepare
8 minutes

Pre-treat
12 minutes

Paint
20 minutes

Dry
10 minutes

Inspect &
Pack
5 minutes

What is the throughput time for this manufacturing process?

The throughput time for the process is 55 minutes

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Prepare
8 minutes

Pre-treat
12 minutes

Paint
20 minutes

Inspect &
Pack
5 minutes

Dry
10 minutes

What is the Bottle neck for this manufacturing process?

The spray painting is the bottleneck in the process

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Prepare
8 minutes

Pre-treat
12 minutes

Paint
20 minutes

Inspect &
Pack
5 minutes

Dry
10 minutes

What is the Cycle time for this manufacturing process?

Cycle time is 20 minutes.The implication of this is that when
the process operates in a continuous manner, a pallet of finished
toys come out every 20 minutes.
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How good is this toy shop?

Utilisation: Ratio of the time that a resource is actually

activated relative to the time that it is available for use
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Work
Station 1

How will you set up this toy shop?

Work
Station 3

Work
Station 2

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Every batch of four toys come out exactly in an interval of 20

minutes
which is the cycle time for the process
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Production Capacity of the system

Prepare
8 minutes
7.5 pallets/hr

Pre-treat
12 minutes

Paint
20 minutes

5 pallets/hr

3 pallets/hr

Dry
10 minutes
(not a
constrained
resource)

Inspect &
Pack
5 minutes
12 pallets/hr

The system can produce at the rate of 3 pallets per hour (12 toys)
For a 8 hour operation the daily production is 24 pallets (72 toys)
Capacity is unbalanced across different stages of the process,,
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Production Capacity under varying resource

availability (2 painting booths)
Existing Scenario: Batch Size of the Process = 1 pallet, 1 painting booth

Prepare
(8 minutes)
7.5 pallets/hr

Pre-treat
(12 minutes)
5 pallets/hr

Paint
(20 minutes)
3 pallets/hr

Dry

Inspect &
Pack
(5 minutes)
12 pallets/hr

Scenario 1: Batch Size of the Process = 1 pallet, 2 painting booths

Prepare
(8 minutes)
7.5pallets/hr
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Pre-treat
(12 minutes)
5 pallets/hr

Paint
(20 minutes)
3 pallets/hr
Dry

Paint
(20 minutes)
3 pallets/hr

Inspect &
Pack
(5 minutes)
12 pallets/hr
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Process Analysis

Some important observations

1. Batch sizes play a crucial role in determining the

bottleneck of a process
2. As several choices are made with respect to the resources
and batch size bottleneck shifts from one stage of the
process to another. This is referred to as wandering
bottleneck.
3. A process analysis exercise often leads to the issue of
improving the process

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Productivity

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Takt Time
Work flow is smoothed out by pacing the work according to
the customer demand.This is called Takt time
2. German word for meter.
3. Example: A business needs to service 10 customers every
hour.
1.

Takt Time = 6 Minutes.

4.

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Aim of the business is to meet the Takt time by adusting

processes.

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Productivity vs. Efficiency

1.

Efficiency : The ratio of the actual output of a process related

to a standard.
Another approach: Measure gain or loss in a process.

2.

Productivity: Ratio of output to input.

Usually in monetary terms.
Partial Productivity

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Assembly Line Balancing

I love Lucy Candy Factory

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Steps : Assembly Line Balancing

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Steps : Assembly Line Balancing

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Example : Line Balancing

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Step 1: Precedence Diagram

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Step 2: Determine Work Station Cycle Time

Step 3: Determine Minimum No of Work station reqd

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