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Manufacturing Models and Metrics.pptx
1.
Ch 3 Manufacturing
Models and Metrics ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Learning Objectives: By the end of the lecture the student should be able to: ■ Apply mathematical models of production performance problems. ■ Explain the concepts of fixed and variable manufacturing costs
2.
Production Concepts and Mathematical
Models ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. ■ Production rate Rp ■ Production capacity PC ■ Utilization U ■ Availability A ■ Manufacturing lead time MLT ■ Work-in-progress WIP
3.
Operation Cycle Time ©2008
Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Typical cycle time for a production operation: Tc = To + Th + Tth where Tc = cycle time, To = processing time for the operation, Th = handling time (e.g., loading and unloading the production machine), and Tth = tool handling time (e.g., time to change tools)
4.
Production Rate ©2008 Pearson
Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Batch production: batch time Tb = Tsu + QTc Average production time per work unit Tp = Tb/Q Production rate Rp = 1/Tp Job shop production: For Q = 1, Tp = Tsu + Tc For quantity high production: Rp = Rc = 60/Tp since Tsu/Q 0
5.
Production Capacity Plant capacity
for facility in which parts are made in one operation (no = 1): PCw = n Sw Hs Rp where PCw = weekly plant capacity, units/wk Plant capacity for facility in which parts require multiple operations (no > 1): PCw = nSwHsRp where no = number of operations in the routing o ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. n
6.
Utilization and Availability Utilization:
U = where Q = quantity actually produced, and PC = plant capacity Availability: A = where MTBF = mean time between failures, and MTTR = mean time to repair PC Q MTBF ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. MTBF MTTR
7.
Availability - MTBF and
MTTR Defined ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
8.
Manufacturing Lead Time
(Batch) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. MLT = no (Tsu + QTc + Tno) where MLT = manufacturing lead time, no = number of operations, Tsu = setup time, Q = batch quantity, Tc cycle time per part, and Tno = non-operation time
9.
Work-In-Process ©2008 Pearson Education,
Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. WIP = where WIP = work-in-process, pc; A = availability, U = utilization, PC = plant capacity, pc/wk; MLT = manufacturing lead time, hr; Sw = shifts per week, Hsh = hours per shift, hr/shift AU PCMLT Sw Hsh
10.
Costs of Manufacturing
Operations ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. ■ Two major categories of manufacturing costs: 1. Fixed costs - remain constant for any output level 2. Variable costs - vary in proportion to production output level ■ Adding fixed and variable costs TC = FC + VC(Q) where TC = total costs, FC = fixed costs (e.g., building, equipment, taxes), VC = variable costs (e.g., labor, materials, utilities), Q = output level.
11.
Fixed and Variable
Costs ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
12.
Manufacturing Costs ©2008 Pearson
Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. ■ Alternative classification of manufacturing costs: 1. Direct labor - wages and benefits paid to workers 2. Materials - costs of raw materials 3. Overhead - all of the other expenses associated with running the manufacturing firm ■ Factory overhead ■ Corporate overhead
13.
Typical Manufacturing Costs ©2008
Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
14.
Overhead Rates Factory overhead
rate: FOHR = Corporate overhead rate: COHR = where DLC = direct labor costs DLC FOHC DLC ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. COHC
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