Process Analysis_Fall 05 Prism Web Pages过程analysis_fall 05棱镜的网页.pptVIP

Process Analysis“If you cannot describe what you are doing as aprocess, you do not know what you are doing.” W.E. Deming Process Analysis Let’s look at the “black box” in more detail… Why do we need to analyze the process? To identify inefficient tasks To spot possible effectiveness improvement tasks To understand where value can be added Process Flow Charts Graphical description of a process: Holding: Raw Materials, RM Work in Process, WIP Finished Goods Inventory, FGI Flow of material or work Processing step Decision point How do we measure capacity? Computing Cycle Times Processing a fixed amount of work Capacity of a process How do we measure throughput time? How do we analyze a complex process… Look at the process step by step Determine throughput rate (i.e. capacity) of each step Identify the process bottleneck (smallest processing rate, or largest cycle time). The capacity of the process is equal to the capacity of the bottleneck Example : hammer production process Process Data: machining: Set up 80 min. 4 min per unit processing. Batch size 200. Identical lines. assembly: Manual by two workers (no set up). Each hammer requires 40 min processing. 34 workers available. pack and ship: 30 min set up, 2 min per unit processing. Lot sizes of 100. Step 1: Machining Look at one line. 200 units require: 80 + 200 ? 4 = 880 minutes/200 units The throughput rate is: 200 / 880 = 0.227 units/minute = 13.63 units/hour But we have two identical lines, so for the machining step capacity is 2 ? 13.63 = 27.26 units/hour. Step 2: Assembly 1 unit requires 40 min processing time, so the throughput rate is: 1 unit / 40 min = 0.025 units/min = 1.5 units/hr 34 workers available, but 2 workers are required for each unit, so assembly capacity is: 17 ? 1.5 = 25.5 units/hr Step 3: Pack and ship Similar to machining: 30 + 100 ? 2 = 230 min/100 units Pack ship capacity is: 100 / 230 = 0.43 units/min = 26.09 units /hr What is a pro