Cycletime Reduction

CYCLETIME REDUCTION
CYCLETIME REDUCTION
Process 1 WIP Process 2 WIP
The Definition of Cycletime

Inspection Pack
Cycletime = Leadtime
1. 2.
Cycletime
There are two general definitions of Cycletime

Time between beginning of production and completion of production. Time between the completion of the last product and completion of the next product.
While the scope of this Course covers BOTH areas, for purposes of clarity, we will refer to definition 1 as leadtime and 2 as cycletime.
CYCLETIME REDUCTION The Definition of Cycletime

Process 1 WIP Process 2 WIP Inspection Pack
Leadtime
Cycletime
The leadtime starts the moment the piece parts are withdrawn from Store and ends when the product is completed. The elements involved : waiting time, processing time, conversion or set-up time, transportation time and documentation time. To effectively reduce leadtime and cycletime, we would need to reduce/eliminate each of these elements.
CYCLETIME REDUCTION The Definition of Cycletime

Cycletime = Available Production Time Number of Products Produced = Production Efficiency
Cycletime can be measured for the whole Production Line, for each individual Product or even Model.
CYCLETIME REDUCTION Importance of Cycletime Reduction

Technology is constantly obsolete Todays Product Lifecycles 3 12 months Inventory is money Risk of inventory obsolescence high Todays Customers want - increased flexibility - low obsolescence risk These goals can be achieved with reduced cycletime A short cycletime is an organizations COMPETITIVE EDGE
CYCLETIME REDUCTION Theory of Constraints A

D
Effective capacity
In a Production line, identify the bottleneck (D). Increase the bottleneck (D) capacity. Bottleneck shifts to B. Increase the bottleneck (B) capacity. To increase the effective capacity, focus on the constraint (bottleneck) area.
Effective capacity
Effective capacity
CYCLETIME REDUCTION Theory of Constraints
Constraints
Product flow Cycletime To REDUCE Cycletime, production flow constraints need to be eliminated or reduced. These constraints are :
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION Cycletime Analysis Tools
Three main tools used to analyze cycletime are :

1.
Flow Diagram
To analyze the actual product flow.
2.
Operations Chart
To analyze every production step and part used.
3.
Process Chart
To study all the handling, inspection, operations, storage and delays as the product flows from raw materials to finished goods.
CYCLETIME REDUCTION Cycletime Analysis Tools
These tools are the macro analysis tools in that they are used to analyze the overall operations.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION
Cycletime Analysis Tools : Diagram
Flow
1. 2.
What it is : A diagram that shows the path traveled by the product as it flows through from Receiving to Production to Shipping. How to develop :
Start with an existing or proposed scaled layout. Each step in the actual or proposed production flow is plotted onto the layout, with arrows showing the direction of flow.
CYCLETIME REDUCTION
Cycletime Analysis Tools : Flow Diagram
Example : A current production layout.

Actual Product Flow Receiving & Issuing Store Shipping Finished Goods Store OQA Room
WIP Awt. Pack WIP (Kits)
Process 1
Assembly Flow
Inspection
Pack
WIP
WIP Awt. OQA
CYCLETIME REDUCTION
The Flow Diagram will be able to identify issues such as :

Cross Traffic where flow lines cross Backtracking where material flows backward Distance product travelled.
CYCLETIME REDUCTION
Cross Traffic and Backtracking

Actual Product Flow Receiving & Issuing Store Shipping Finished Goods Store OQA Room
Backtracking
Cross Traffic WIP (Kits) Process 1 Assembly Flow Inspection
WIP Awt. Pack
Pack
WIP
WIP Awt. OQA
CYCLETIME REDUCTION
Cycletime Analysis Tools : Operations Chart
What it is : A chart showing the raw material, the purchased piece parts, the fabrication/sub-assembly sequence, the assembly sequence, the equipment needs and the time standards to produce a finished product.
CYCLETIME REDUCTION
1. 2.
How to develop :
Identify purchased vs. sub-assembled piece parts. Determine the operations required to fabricate each part and its sequence of operations. Determine the sequence of assembly for ALL piece parts. Identify the base part (raw PCB). This is the 1st part that starts the assembly process. Put that part on a horizontal line at the far right top of the page. On a vertical line extending down from the right side of the horizontal line, place a circle for each operation. Beginning with the first operation, list all operations down to the last operation. Place the 2nd part to the left of the 1st part and the 3rd part to the left of the 2nd part etc. All of the fabrication steps are listed below the parts with a circle representing each operation. Draw a horizontal line from the bottom of the last operation of the 2nd part to the point above the operation where it joins the 1st part, and so on.
3. 4.
5.
6.
CYCLETIME REDUCTION

Purchased Piece Part
Example :
4th Part
Parts to be fabricated
3rd Part
2nd Part
1st Part / Base Part
Operations to fabricate 4th Part
Sub-assemble 4th Part to 3rd Part
Assemble 1st and 2nd Parts and sub-assemble 3rd and 4th Parts
CYCLETIME REDUCTION
7. 8. 9.
How to develop : cont.

Introduce all the purchased piece parts on horizontal lines above the assembly operation circle where they are placed on the assembly. Put time standards, operation numbers, and operation descriptions next to and in the circle. Sum total the hours per 1,000 units and place these total hours at the bottom right under the last assembly or pack-out operation.
Solder paste PCB
Example :
Caps 0012 (4) Res. 0120 (3)
Units per hour

400
Solder paste printing SMD placement
05
Operation description
10
Number of hours to complete 1,000 250 units

2.5
4 6.5 hours
Operation number
CYCLETIME REDUCTION
From the Operations Chart, the theoretical product leadtime can be determined. The difference between the actual leadtime and the theoretical leadtime is the leadtime GAP. It is only through process and operations improvement that the theoretical leadtime can be improved.
CYCLETIME REDUCTION
Cycletime Analysis Tools : Process Chart

What it is : A chart that shows all the handling, inspection, operations, storage, and delays that occur to one part as it moves through the Production process.
How to develop : Conventional symbols are used to describe the process steps.
Description Circle Square Indicates Operation Inspection Meaning Performing work on a part Used for quality control work Used when moving material Used for long term storage Used for short term storage
Symbol
Arrow
Triangle
Transportation
Storage Delay
Big D
CYCLETIME REDUCTION

Sample Process Charting
PROCESS CHART
PRESENT METHOD PART DESCRIPTION :
PROPOSED METHOD
DATE :
PAGE
2
OPERATION DESCRIPTION :
3
SUMMARY
OPERATIONS TRANSPORT INSPECTIONS PRESENT NO. TIME PROPOSED NO. TIME DIFFERENCE NO. TIME WHY WHAT WHERE ANALYSIS : WHEN WHO HOW FLOW DIAGRAM ATTACHED
DELAYS STUDIED BY : FT.

METHOD
STORAGES DIST. TRAVELED STEP DETAILS OF PROCESS
FT.
FT.
DELAY STORAGE
OPERATION TRANSPORT INSPECTION
DISTANCE
QTY
HRS/UNIT
TIME CALCULATIONS
1 2
D D D
10 11 12
13
CYCLETIME REDUCTION
1.
2. 3. 4.

The main sections :
Select either present method or proposed method, date and page. Describe the name of part and specifications if relevant. Record the limits of the study (example : from Receiving to FG). Record under the PRESENT column for study of current operations. To come up with a new proposal, use the PROPOSED column. For each step, the 5Ws and 1H are asked, starting with Why. Try to

5.
Eliminate every step possible or Combine the steps or Change the sequence of operations to improve the product flow.
6. 7. 8. 9.
A Flow Diagram should be attached if available. Describe what happens in each step. Methods of transportation or storage are described (eg. by pallet). Symbols shade the appropriate symbol related to the step.
CYCLETIME REDUCTION

The main sections :
10.
11.
12.
13.
This is recorded when the transportation symbol is used. Specify unit of measurement. Quantity refers to many things : a. Operations Pieces per hour b. Transportation Number of pieces moved at a time c. Inspection Pieces per hour and/or frequency of inspection d. Delays Number of pieces waiting e. Storage How many pieces per storage unit Hours per unit time spent per piece at that step. Used only for operations, transportation and inspection. Time calculations column provided to compute time spent.
Once all the sections are completed, return to complete the Summary. Use your Process Chart analyze and identify improvement opportunities.
CYCLETIME REDUCTION
Methods of Analyzing Cycletime

Five main charts are used to micro analyze cycletime of operations : Operations Analysis Chart Operator/Machine Chart Gang Chart Multi-Machine Chart Left/Right Hand Chart
CYCLETIME REDUCTION
Methods of Analyzing Cycletime

These charts are used to analyze and breakdown each operation into its separate micro elements.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION
Methods of Analyzing Cycletime :Multi Activity Chart

What it is : It is a standard Chart Format used to create the

Operations analysis chart Operator/machine chart Gang chart Multimachine chart Left-hand/right-hand chart
The chart is separated into 15 different sections.
CYCLETIME REDUCTION
1

MULTI ACTIVITY CHART
OPERATOR/MACHINE GANG MULTI MACHINE LEFT HAND/RIGHT HAND OPERATIONS 2 3 OPERATION NO. PART NO. OPERATION DESCRIPTION : 7 4 5 DATE : TIME :
BY :
6 8 9
TOTAL UTILIZATION : % UTILIZATION :
ACTIVITY
TIME IN SECONDS
ACTIVITY
8 9
10
TOTAL UTILIZATION :
10
TOTAL NORMAL TIME IN SECONDS PER UNIT : + % ALLOWANCE :
12
11
% UTILIZATION :
STANDARD TIME : HOURS PER UNIT : PIECES PER HOUR :
15
14
13
CYCLETIME REDUCTION
1. 2. 3. 4. 5. 6. 7. 8.
1. 2. 3. 4.

The main sections :
Tick or cross the appropriate box on the chart being created. The operation number for the particular operation (if available). The product part number. The date of the study, include day, month and year. The time the study started. Record the name of the person who is conducting the study. Operation described in clear terms. Activity will represent different things for different charts
Operations analysis use LEFT column only Operator/machine LEFT column for Operator, RIGHT for Machine Gang LEFT column for Operator 1, RIGHT for Operator 2 Multimachine 2 charts are taped next to each other. On the 1 st chart, LEFT column for Operator, RIGHT for Machine 1. On the 2nd chart, LEFT column for Machine 2, RIGHT column for Machine 3. L-H/R-H LEFT column for Left Hand, RIGHT for Right Hand
5.
CYCLETIME REDUCTION

The main sections :
9. 10. These are the activity areas where the actual activities are recorded. Total Utilization is how much time this activity was working. Idle time is NOT included. % Utilization is the total utilization divided by the total time of that activity. Total normal time is how long it takes each activity to complete a cycle and includes both working time and idle time. Allowances are the time added to normal time to make the time standards realistic. These include personal time, fatigue and delays. A ballpark figure of 10% is typically used. Standard time = normal time + allowances (in secs/unit). Hours per unit = standard time (secs/unit)/(3600 secs/hour) Pieces per hour = inverse of hours per unit = 1/(hours per unit)
11.
12.
13. 14. 15.
CYCLETIME REDUCTION
Methods of Analyzing Cycletime Pieces Per Hour Cycletime
Pieces Per Hour
Cycletime
1 Hour
Cycletime
Cycletime
CYCLETIME REDUCTION
Methods of Analyzing Cycletime :Operations Analysis Chart

What it is : A chart used to describe

a single activity usually one operator using tools 100% operator controlled Example : Packing operation.

OPERATOR/MACHINE GANG LEFT HAND/RIGHT HAND
OPERATION NO. DATE : BY : PART NO. TIME :
MULTI MACHINE OPERATIONS

X AX250 TIME IN 0930
ACTIVITY
100 Feb.26,05
ACTIVITY
Bruce Lee
SECONDS
Packing operation for shipment.
CYCLETIME REDUCTION Methods of Analyzing Cycletime Operations Analysis Chart

Activity
10 4 7
Fold carton box, insert kimcell. Insert PCBA and pack into carton. Idle. This side is left blank
SECONDS
Activity
These activities need to be analyzed, for example : Why 10 secs to prepare box? Can it be prepared ahead of time? Why idle time of 7 secs? How to eliminate this? What can operator do if cannot eliminate?
CYCLETIME REDUCTION Methods of Analyzing Cycletime Operations Analysis Chart

14 secs 67%
21 secs 10% 24 secs 0.0067
150
TOTAL UTILIZATION : % UTILIZATION : TOTAL NORMAL TIME IN SECONDS PER UNIT : + % ALLOWANCE :
CYCLETIME REDUCTION Methods of Analyzing Cycletime Operator/Machine Chart
What it is : A chart that shows the activities and inter-relationship of the operator and the machine. The chart shows what each is doing at any moment in time.
Example : An operator running a marking machine. MULTI ACTIVITY CHART

OPERATOR/MACHINE GANG LEFT HAND/RIGHT HAND
PART NO. TIME :

75 OPERATION NO. Feb.26,05 DATE :

BY :
BY300 1500
Ink marking EPROM.
Jackie Chan Operator
ACTIVITY
TIME IN SECONDS
ACTIVITY
Ink Mark Machine

Operator
SECONDS
Ink Mark Machine Idle. Mark unit. Idle.
5 7 4 5
Load EPROM. Idle. Unload EPROM. Inspect EPROM.
5 7 9
Can the work sequence be rearranged to utilize the idle time to do inspection?
The high percentage of idle time represents a waste of capacity. How to minimize?
Can the inspection be eliminated to reduce the cycletime?

14 secs 67%
21 secs 10%
7 secs 33%
24 secs 0.0067
150
CYCLETIME REDUCTION Methods of Analyzing Cycletime Gang Chart
What it is : A chart to show the activities of two or more people when their activities intertwine. When more than two people are involved, tape two or more charts side by side.
Example : Solder joint touch-up and inspection.

X OPERATOR/MACHINE GANG LEFT HAND/RIGHT HAND
OPERATION NO. 85 DATE : Feb.26, 05 BY : PART NO. LT800 TIME : 1700

Solder joint touch-up and inspection.
Ali Bakar Touch-up operator
ACTIVITY
TIME IN SECONDS
ACTIVITY
Inspection operator

Touch-up operator
SECONDS
Inspection operator Picks up unit. Inspects for solder joint defects. Passes unit to touch-up operator. Idle.
16
Idle.
Touch-up solder joints. Returns unit to inspection operator.
12 4 26 11
26 11
Idle.
Inspects touched up unit.
All the idle time add up to one operator time. Does it make sense to train one operator to perform both these tasks to reduce the cycletime as well as the idle time?

26 secs
49% 53 secs 10%
27 secs
51%
59 secs 0.016
63
CYCLETIME REDUCTION Methods of Analyzing Cycletime Multi-Machine Chart
What it is : A chart similar to the operator/machine chart except that additional charts are taped to the side of the 1st chart. On these additional charts, each additional machine takes up one column.
Example : 1 operator running 3 ink markers.
Operator
Machine 1
Machine 2
Machine 3
CYCLETIME REDUCTION Methods of Analyzing Cycletime Left/Right Hand Chart
What it is : A chart that tracks the separate activities of each hand of an operator. Each hands activity is broken down into detailed elements.
Example : Operator inserting PTH components into PCBA.

OPERATOR/MACHINE GANG LEFT HAND/RIGHT HAND X
OPERATION NO. 65 Feb.26, 05 DATE : BY : PART NO. TIME :

AT540 1030
Muru Left Hand
PTH insertion into PCBA.
ACTIVITY
TIME IN SECONDS
ACTIVITY
Right Hand

5 12 13
Left Hand Pick-up PCBA. Idle (Holding PCBA). Idle.
SECONDS
Right Hand Pick-up component. Align and insert component into PCBA. Pass PCBA to next operation. Idle.
5 12 4 9

5 secs 17%
30 secs
21 secs 70%
10% 33 secs 0.009
109
CYCLETIME REDUCTION Methods of Cycletime Reduction Work Station Design
Having a work station that is designed to ease the task of the operator will help in maximizing work efficiency = reducing cycletime. A well designed work station supports motion economy.
Process 1 WIP
Process 2 WIP
Inspection
Pack
Some key considerations :
Work station tables to promote mirror image hand motions. Component trays should be located between normal reach and maximum reach positions of the operator. Ideal lighting position is over the work area and slightly over the back (to avoid glare). Properly located lighting will reduce fatigue.
Light Location
Work table height should be constant and ideally at elbow height of the seated person.
Use chairs which can be adjusted for height. Chairs should be comfortable with back supports.
Frequently used tools should be located nearby the work station. Incorporate fixtures to replace the human hand for holding parts as much as possible. Locate reject bins or baskets close to the work station to prevent unnecessary movement by the operator. Use chutes to take advantage of gravity to move parts.
Align the work station to the product flow.
CYCLETIME REDUCTION Methods of Cycletime Reduction Motion Economy
Economic motion minimizes processing time and hence contributes to cycletime reduction. This is strongly related to and supported by work station design.
Process 1 WIP
Process 2 WIP
Inspection
Pack
1. 2.

The hands should :
Operate as mirror images Start and stop motions at the same time Move in opposite directions Be working at all times.
3.
4.
Use fixtures to replace hands holding parts where possible. Use foot operated control devices where possible to free up the hands.

Use ballistic motions where possible : fast motions using one set of muscles and not trying to end the motion using other muscles, example, throwing a part into a bin. Use controlled motions, i.e. which require control at the end of the motion, only for activities needing safety or quality considerations. Use curved continuous motions instead of separate linear motions.
CYCLETIME REDUCTION Methods of Cycletime Reduction Line Balancing
One technique which sees almost immediate impact in a cycletime reduction exercise is line balancing. By balancing the production line, obvious line imbalances or bottlenecks can be removed. This increases the effective line capacity and reduces cycletime. Refer to section on Theory of Constraints.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION Methods of Cycletime Reduction Removing NVA

Non-Value-Added activities are activities that do not add value to the product. They just add cost. Major NVA activities are inspection, product movement and waiting time. By removing or reducing these activities, the cycletime is reduced accordingly. Waiting time is one of the major contributors to long cycletime.
Process 1 WIP
Process 2 WIP
Inspection
Pack
While removing inspection needs to be justified with quality improvement, others such as eliminating a staging area (shown below), can be easily justified.
STAGING AREA
ISSUING STORE
PRODUCTION LINE ISSUING STORE
PRODUCTION LINE
Examples of elimination of handling and transportation. Improvement from A to D.
A
Double Handling
Transportation
C
Inventory on conveyor
D
No waiting
CYCLETIME REDUCTION Methods of Cycletime Reduction Quick Set-ups
In handling multiple models, the process of changing from one model to the next is NVA. It adds up to the product leadtime and hence, cycletime. Quick set-ups, therefore, reduce product cycletime.
Process 1 WIP Process 2 WIP Inspection Pack
Internal setup : Setup activities done on the machine while the machine is down.
Example : Changing over of tools, dies, jigs and materials while the machine is down.
External setup : Setup activities done before and after the machine is down and do not add to the machine downtime.
Example : Preparing in advance the necessary jigs, tools, the next die and materials and removing the detached die and jigs after the machine is up. Machine down Machine up External setup remove detached tool, die
External setup prepare tool, die, materials
Internal setup change tool, die, materials

Steps in Shortening Set-up Time
1. Separate the internal set-up tasks from the external setup tasks
Example :
Typical External Set-up Tasks Preparation of dies, fixtures etc. Transfer of dies
Typical Internal Set-up Tasks Attachment and detachment Adjustment of location, height, pressure, etc. Test run
2. Convert internal set-up to external set-up

Example : Preheating dies is a way of converting internal set-up to external set-up

3. Improve internal set-up Example 1 : Reduce internal set-up by eliminating adjustment Standardized Die Height
Blocks
Locating Pin

4. Improve external set-up
Reduce/eliminate time wasted searching for tools, dies and fixtures by designating areas by color coding shelves and assigning addresses for each storage area.
Reduce time wasted in transferring dies by storing frequently used dies close Address to the machine.
88B
Color coding
Machine
Die storage area (close to the point of use)
CYCLETIME REDUCTION Methods of Cycletime Reduction Lot Size Reduction
Typically, the larger the lot size, the longer the waiting time. Traditionally, large lot sizes were preferred due to high set-up times. However, with large lot sizes, WIP builds up and product cycletime lengthens. Reducing lot size reduces product cycletime.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION Methods of Cycletime Reduction Lot Size Reduction
Example : Processing time 1 min./unit

Lot size : 3
A A A B B B C C C
Time
0 min
Time
0 min 1 min 2 min 3 min 4 min A A
Lot size : 1
B B C C
3 min
6 min
A
A A A
B
B B B
C
C C C
9 min
5 min
CYCLETIME REDUCTION Methods of Cycletime Reduction Parallel Processing
Parallel processing means processing 2 or more operations at the same time. In set-up time language, it means converting internal time to external time. Parallel processing, therefore, reduces set-up time.
Process 1 WIP
Process 2 WIP
Inspection
Pack

Example : Reducing internal set-up by using Parallel Operations Parallel Operations on a Press Machine
machine stop Step No. 1 2 3 4 5 6 7 1 2 3 4 Internal/ External I I I I I I I 5 6 7 machine start Required time (min) Performed by 3 Operator 10 Operator 2 Operator 2 Operator 10 Operator 20 Operator 10 Operator
Operation Look for new die Transfer new die Remove used die Attach new die Transfer new material Adjust Transfer used die
Before improvement (Total Internal Set-up Time : 57 Min)

1 2 5 4 3 machine stop Internal/ Operation External Look for new die E Transfer new die E Transfer new material E Attach new die * I Adjust ** I Remove used die * I Adjust ** I Transfer used die E 6a 6b 7 (Set-up assistant) (Operator) machine start Required time (min) Performed by 3 Assistant 10 Assistant 10 Assistant 2 Assistant 7 Assistant 2 Operator 8 Operator 10 Assistant
Step No. 1 2 5 4 6a 3 6b 7
Note : *, ** : conduct operations simultaneously
After improvement (Total Internal Set-up Time : 10 Min)
CYCLETIME REDUCTION Methods of Cycletime Reduction WIP Reduction
Work In Progress (WIP) or inventory, when not being processed, is accumulating cycletime. Therefore, to reduce cycletime, drive down WIP.
Process 1 WIP
Process 2 WIP
Inspection
Pack

Raw material Sea of inventory
Finished products to customers
Machine breakdown Poor scheduling Long set-up times
Quality problems
Absenteeism
Inventory Covers Problems

The only justifiable WIP is that which is used to prevent a process from being linedown. For example, the WIP shown should only serve to prevent Process 2 from stopping because of instability in Process 1 due to :
Process 1 WIP
Process 2
Machine downtime Low yields Quality issues Batch processing waiting time
However, as WIP represents waiting inventory and should be driven down.
CYCLETIME REDUCTION Methods of Cycletime Reduction FIFO
FIFO stands for First In First Out. This is a flow sequence where the first product processed flows through and gets completed first, and so on. By implementing FIFO, no WIP gets bypassed and line issues are forced to be addressed, easing the subsequent product flow and hence reducing cycletime. The only time FIFO should be bypassed is when there is an abnormal lot such as extremely low yield lot, quality question etc.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION Methods of Cycletime Reduction Kanbans

A Kanban is a card used in the Toyota Production System or JIT. It is used to request or pull materials in a Pull Production System. In Malaysia, typically Kanban squares are used in the place of Kanban cards. By defining the Kanban quantity, WIP, production flow and hence cycletime can be controlled.
Process 1 WIP
Process 2 WIP
Inspection
Pack
What is the Kanban system? An information system that harmoniously controls the production of the necessary products in the necessary quantities at the necessary time in every process of a factory and also among companies It utilizes a pull system that is dictated by customer orders It is a sub-system that supports the Toyota Production System or lean manufacturing

PROCESS 1 WIP PROCESS 2 WIP FG STORE FG CUSTOMER
3 Process 1 receives a Production Ordering Kanban from its Kanban location.
2 Process 2 receives a Production Ordering Kanban from its Kanban location.
1 Customer places order and FG Store ships FG available to Customer. At the same time, a Withdrawal Kanban is issued from FG Store to Kanban location of Process 2 and WIP from Process 2 is pulled to FG Store
It starts production and at the same time issues a Withdrawal Kanban to Kanban location of Raw Matl Store
It starts production and at the same time issues a Withdrawal Kanban to Kanban location of Process 1
CYCLETIME REDUCTION Methods of Cycletime Reduction Leveled Production
When there are two models to a product, say models A and B. Typically, these models will be loaded as A,A,A,A then B,B,B,B. In leveled production, the loading is A,B,A,B,A,B,A,B. The advantage of leveled production with regards to cycletime is huge if A and B are sold as a set.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION Methods of Cycletime Reduction Leveled Production
Example : Models A and B (a set) are processed through Processes 1 and 2. Each take 1 minute to process for each process. Two sets are processed.
Time Time 1 A A B B 2 1 min A A A B A A 2 min 3 min 4 min 1 A B A B 2
1 min 2 min 3 min 4 min
1
1 1
2
2 2
1
1 1
2
2 2
A B A A B A
Set completion : 4 min
Set completion : 3 min
CYCLETIME REDUCTION Methods of Cycletime Reduction Eliminating Wastes
Wastes are elements in the Production area that add cost but not value. Eliminating these wastes will see the cycletime drop tremendously.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION Methods of Cycletime Reduction Eliminating Wastes
Kiyoshi Suzaki refined waste classification into seven categories : Waste from overproduction Waste of waiting time Transportation waste Processing waste Inventory waste Waste of motion Waste from product defects Henry Ford, If it doesnt add value, its waste.
CYCLETIME REDUCTION Methods of Cycletime Reduction Flow Smoothing / Layout
Like water flowing through a pipe, a short and direct production layout will tend to produce a smooth and fast production flow. Use a product-centric layout instead of a process-centric layout to shorten product cycletime.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION Methods of Cycletime Reduction Flow Smoothing / Layout
Layout/flow guidelines :

Product should flow towards the shipment area. No backflow where possible. No cross flows. Do not use excess floor space. Keep area compact and defined. Identify all inventory areas and kanbans.
SHIPMENT SHIPMENT
SHIPMENT SHIPMENT
WALLED OFF FOR FUTURE EXPANSION
SHIPMENT
CYCLETIME REDUCTION Methods of Cycletime Reduction 5S

A properly executed 5S environment can help reduce cycletime. A neat and properly defined work area means that tools and parts can be easily found. Searching time and waiting time can be minimised or eliminated resulting in reduced cycletime.
Process 1 WIP
Process 2 WIP
Inspection
Pack
CYCLETIME REDUCTION Cycletime Simulation
A cycletime simulation can reveal the theoretical leadtime and cycletime for the product. This will be the theoretical limit for the product cycletime.
Define the lot size, the processes and the UPH for each process. Compute the lot completion time for each process. List the Processes down the first column. List an Hour timeline across the top row. Plot the Lots as they move diagonally down from top left to bottom right of the table.
1. 2. 3. 4. 5.

Lot Size : 3,000
1
Process UPH Lot Completion Time
Assembly 1,200 2.50
Mark 2,000 1.50
Test 1,500 2.0
2 Lot Completion Time = Lot Size
UPH

Timeline (hr) Process Assembly 3 Mark
1 2 3 4 5 6 7 8 9 10 11
4
Lot 1 Lot 2 Lot 1 Lot 1 Lot 3 Lot 2 Lot 2 Lot 3 Lot 3
Test
Leadtime = 6hrs
Cycletime = 2.5hrs
Cycletime
CYCLETIME REDUCTION Cycletime Metrics
Metrics related to cycletime are :

Total leadtime Cycletime Process Cycle Efficiency (PCE) Workstation Turnover Time (WTT)
PCE Process 1 WIP Process 2 WIP Inspection WTT Pack
Total Leadtime
Cycletime
Total Leadtime

Unit of measurement weeks/days/shifts/hours/mins Total leadtime can be :
measured (from time piece parts are issued to receiving completed product at Finished Goods) computed from Littles Law :
WIP (units) Average Completion Rate Effective Line Capacity (units/time)
Total Leadtime (time) =
Cycletime

Unit of measurement weeks/days/shifts/hours/mins Although cycletime is defined as the time taken for the next product to be produced, the average cycletime is generally computed as follows :
Cycletime (time/unit)= Available Production Time (time) Number of Products Produced (unit)
Process Cycle Efficiency (PCE)
PCE indicates how efficiently the process is converting WIP into finished products. PCE is a ratio. Any process with low PCE will have large NVA activities and hence opportunities to for cycletime reduction. It is common to get PCEs of less than 10% before improvement. The Process Chart can be used to collect the required data for Value-Add Time.
Value-Add Time (time) Total Leadtime (time)
PCE =
Workstation Turnover Time (WTT)

It is the time taken to set-up and perform one cycle of work at a specified workstation. Unit of measurement - hours/mins/secs.
Summation of (set-up time + process time) at the workstation
WTT =

Cycletime Reduction

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Cycletime Reduction

Загружено:

Авторское право:

Доступные форматы

CYCLETIME REDUCTION

The Definition of Cycletime

There are two general definitions of Cycletime

CYCLETIME REDUCTION The Definition of Cycletime

CYCLETIME REDUCTION The Definition of Cycletime

CYCLETIME REDUCTION Importance of Cycletime Reduction

CYCLETIME REDUCTION Theory of Constraints A

CYCLETIME REDUCTION Theory of Constraints

CYCLETIME REDUCTION Cycletime Analysis Tools

Three main tools used to analyze cycletime are :

CYCLETIME REDUCTION Cycletime Analysis Tools

Cycletime Analysis Tools : Flow Diagram

Example : A current production layout.

WIP Awt. Pack WIP (Kits)

WIP Awt. OQA

Cycletime Analysis Tools : Flow Diagram

The Flow Diagram will be able to identify issues such as :

Cycletime Analysis Tools : Flow Diagram

Cross Traffic and Backtracking

Cross Traffic WIP (Kits) Process 1 Assembly Flow Inspection

WIP Awt. Pack

WIP Awt. OQA

Cycletime Analysis Tools : Operations Chart

Cycletime Analysis Tools : Operations Chart

Cycletime Analysis Tools : Operations Chart

1st Part / Base Part

Operations to fabricate 4th Part

Sub-assemble 4th Part to 3rd Part

Cycletime Analysis Tools : Operations Chart

How to develop : cont.

Units per hour

Solder paste printing SMD placement

Number of hours to complete 1,000 250 units

Cycletime Analysis Tools : Operations Chart

Cycletime Analysis Tools : Process Chart

Cycletime Analysis Tools : Process Chart

DELAYS STUDIED BY : FT.

STORAGES DIST. TRAVELED STEP DETAILS OF PROCESS

OPERATION TRANSPORT INSPECTION

Cycletime Analysis Tools : Process Chart

Cycletime Analysis Tools : Process Chart

Methods of Analyzing Cycletime

Methods of Analyzing Cycletime

Methods of Analyzing Cycletime :Multi Activity Chart

The chart is separated into 15 different sections.

Methods of Analyzing Cycletime :Multi Activity Chart

TOTAL NORMAL TIME IN SECONDS PER UNIT : + % ALLOWANCE :

STANDARD TIME : HOURS PER UNIT : PIECES PER HOUR :

Methods of Analyzing Cycletime :Multi Activity Chart

Methods of Analyzing Cycletime :Multi Activity Chart

13. 14. 15.

Pieces Per Hour

Methods of Analyzing Cycletime :Operations Analysis Chart

MULTI ACTIVITY CHART

MULTI MACHINE OPERATIONS

X AX250 TIME IN 0930

Packing operation for shipment.

CYCLETIME REDUCTION Methods of Analyzing Cycletime Operations Analysis Chart

CYCLETIME REDUCTION Methods of Analyzing Cycletime Operations Analysis Chart

TOTAL UTILIZATION : % UTILIZATION :

STANDARD TIME : HOURS PER UNIT : PIECES PER HOUR :

CYCLETIME REDUCTION Methods of Analyzing Cycletime Operator/Machine Chart

Example : An operator running a marking machine. MULTI ACTIVITY CHART