batch flow process

8/3/2019 Batch Flow Process

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BATCH FLOW PROCESSBATCH FLOW PROCESS

Course InstructorCourse Instructor

Dr. N. SambandamDr. N. Sambandam

______________________________________________________________________________________________

NATIONAL INSTITUTE OF INDUSTRIAL ENGINEERINGNATIONAL INSTITUTE OF INDUSTRIAL ENGINEERING

ViharVihar Lake, Mumbai 400 087.Lake, Mumbai 400 087.


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PRODUCTS AND VOLUMEPRODUCTS AND VOLUME

Produce low volumes of variety of differentproducts.

Investment in specialized machines andtools is justified.Orders: one time for small qty. and repeat fromtime to time.

ExamplesExamples: Home heating systems, Tanks formilitary, Ice cream, Forest harvest equipments,Suit coat, sport coat, Kitchen & dinning room

furniture,Pharmaceutical products.


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LAYOUT AND MATERIAL FLOWLAYOUT AND MATERIAL FLOW

Cellular layout/Functional layout.Employees work in more than one department and are skilled

on many equipments.Equipment and tooling are special purpose a (lower overhead).Material flow through the shop do not differ for each job.Work-in-process inventory is low.Delivery times are not long.

Setup time is low.Batch (or lot) size decides the workload in the shop.Scheduling is important but is simpler than job shop.


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Materialsordering

Spreading

Reproducingthe marker

CuttingFitting andSoabaring

Fitting

Fitting

Materialsreceipts

Majormatching

Subassembly

Subassembly

Othersubassembly

Majormatching

Finalassembly

Pressingand

inspection

sleeves

fronts

backs

collars

Welts, etc

To coatshop

To skirtshop

CoatShop

Serging

Outside pleating

RemainingSkirt operations

Pressing andinspection

Warehouse matchingOf coat and skirt

Skirtshop

Todistributor

Figure: a Simplified process flow diagram


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Operations flow chartOperations flow chart

Shoulderjoint

Frontpairing

Buttonplacket


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Operations descriptionOperations description

Work station #4 , operation: TrimmingWork station #4 , operation: Trimming

A set of collar parts is taken from stand and put onA set of collar parts is taken from stand and put onthe LHS area of the work stationthe LHS area of the work station

A collar neck band part is taken by left handA collar neck band part is taken by left hand The part is put under the presser foot of trimmingThe part is put under the presser foot of trimming

m/c by using both hands.m/c by using both hands.

The part is trimmed by machine by pivoting itThe part is trimmed by machine by pivoting it

wherever necessarywherever necessary The trimmed part is put on legs by right handThe trimmed part is put on legs by right hand

A batch of trimmed parts is taken from legs and putA batch of trimmed parts is taken from legs and puton the standon the stand


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Determination ofDetermination of smvsmv &&

ThroughputThroughput TotalTotal smvsmv= sum of all ten readings(seconds)/60= sum of all ten readings(seconds)/60

AverageAverage smvsmv= Total= Total smvsmv/10/10

Std time =Std time = AvgAvg time(time(avgavg smvsmv)*allowance)*allowance

Allowance = 15% (for machine operation)Allowance = 15% (for machine operation)= 12%(for manual operation)= 12%(for manual operation)

Capacity per hour(Throughput)= 60/std timeCapacity per hour(Throughput)= 60/std time


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Path lengthPath lengthpath: collar to end line(length= 10.53 m)path: collar to end line(length= 10.53 m)

Shoulderjoint

Frontpairing

Buttonplacket


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Path : collar band to end line checkingPath : collar band to end line checkinglength= 9.05 minuteslength= 9.05 minutes

Shoulderjoint

Frontpairing

Buttonplacket


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Path: front right to end line checkingPath: front right to end line checkingpath length= 9.62 minutespath length= 9.62 minutes

Shoulderjoint

Frontpairing

Buttonplacket


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Path: front right to end line checkingPath: front right to end line checkingpath length= 9.56 minutespath length= 9.56 minutes

Shoulderjoint

Frontpairing

Buttonplacket


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Path: pocket to end line checkingPath: pocket to end line checkingpath length= 10.37 minutespath length= 10.37 minutes

Shoulderjoint

Frontpairing

Buttonplacket


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Path: back to end line checkingPath: back to end line checkingpath length= 9.764 minutespath length= 9.764 minutes

Shoulderjoint

Frontpairing

Buttonplacket


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Path: sleeve placket to end linePath: sleeve placket to end linecheckingchecking

path length= 8.68 minutespath length= 8.68 minutesCollar trim Collar run Collar trim Collar turn Collar

edge levelCollar iron Collar top

Band hem Band set Band set

top

Collar

inspection

Plackettrim

Frontplacket

Frontbutton hole

Pocketattach

Pocketiron

Pocketiron & trim

Pockethem

Main labelattach Small labelattach Yokeattach Yoke iron& trim

Shoulderjoint

Sleeveplacket

SleeveBartac

Sleeve boxSleeve

button hole

Cuff hem Cuff runCuff turn& edge

Cuff top

Collar attach

Collar finishing

Sleeve attach

Sleeve top

Side seam

Cuff matchingand marking

Checking &trimming

Frontbuttonattach

Buttonmarking

Collar &cuff button

holeBottom

hemCuff attach

Frontpairing

Buttonplacket


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Path: cuff to end line checkingPath: cuff to end line checkingpath length= 6.113 minutespath length= 6.113 minutes

Collar trim Collar run Collar trim Collar turn Collaredge level

Collar iron Collar top


top

Collar

inspection

Plackettrim

Frontplacket

Frontbutton hole

Pocketattach

Pocketiron

Pocketiron & trim

Pockethem


Shoulderjoint

Sleeveplacket

SleeveBartac

Sleeve boxSleeve

button hole


Cuff top

Collar attach

Collar finishing

Sleeve attach

Sleeve top

Side seam


Checking &trimming

Frontbuttonattach

Buttonmarking

Collar &cuff button

holeBottom

hemCuff attach

Frontpairing

Buttonplacket


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Critical pathCritical path

The path having maximum time lengthThe path having maximum time length

i.e. if all the parts of the shirt are put into the line fori.e. if all the parts of the shirt are put into the line fortheir respective operations at the same time thentheir respective operations at the same time thenthe part which is coming through the path which isthe part which is coming through the path which istaking maximum time will decide the throughputtaking maximum time will decide the throughputtime of the line , this path is called as critical pathtime of the line , this path is called as critical path

So here critical path: the path coming from collar toSo here critical path: the path coming from collar toend line checkingend line checking

Critical path length= 10.53 minutesCritical path length= 10.53 minutes


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Critical pathCritical pathcritical path length=10.53 minutescritical path length=10.53 minutes




top

Collar

inspection

Plackettrim

Frontplacket

Frontbutton hole

Pocketattach

Pocketiron

Pocketiron & trim

Pockethem


Shoulderjoint

Sleeveplacket

SleeveBartac

Sleeve boxSleeve

button hole


Cuff top

Collar attach

Collar finishing

Sleeve attach

Sleeve top

Side seam


Checking &trimming

Frontbuttonattach

Buttonmarking

Collar &cuff button

holeBottom

hemCuff attach

Frontpairing

Buttonplacket


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Work balancing among workWork balancing among workstations to achieve the requiredstations to achieve the required

targettarget Search for the bottleneck operationsSearch for the bottleneck operations

Bottleneck decides the capacity of theBottleneck decides the capacity of thelineline

E.g. what is the capacity of this line?E.g. what is the capacity of this line?

Op1(100) Op2(90) Op3(115) Op4(120)


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Work balancing.Work balancing. continuedcontinued

Operation with least capacity isOperation with least capacity is

sleeve placketsleeve placket

SMV=1.18 minutesSMV=1.18 minutesCapacity = 44 units per hourCapacity = 44 units per hour

But it will not be considered asBut it will not be considered asbottleneck because it does not lie onbottleneck because it does not lie onthe critical paththe critical path


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Critical pathCritical pathcritical path length=10.53 minutescritical path length=10.53 minutes




top

Collarinspection

Plackettrim

Frontplacket

Frontbutton hole

Pocketattach

Pocketiron

Pocketiron & trim

Pockethem


Shoulderjoint

Sleeveplacket

SleeveBartac

Sleeve boxSleeve

button hole


Cuff top

Collar attach

Collar finishing

Sleeve attach

Sleeve top

Side seam


Checking &trimming

Frontbuttonattach

Buttonmarking

Collar &cuff button

holeBottomhem

Cuff attach

Path from sleeve

placket have thelead of 1.84 mover the critical

pathLeast

capacitySMV=1.1

8 m &capacity

=44 u ph

Frontpairing

Buttonplacket


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Work balancing Work balancing Next operation having the least capacityNext operation having the least capacity

Cuff attachCuff attach

SMV = 1.145 minutesSMV = 1.145 minutes

Capacity = 45 units per hourCapacity = 45 units per hour

It lies on the critical pathIt lies on the critical path

So considered as bottleneck operationSo considered as bottleneck operation

So affects the line capacity, because changes in theSo affects the line capacity, because changes in thesmvsmv value of this operation will have effect onvalue of this operation will have effect on

critical path lengthcritical path length


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Work balancing..Work balancing..Ways to improve bottleneckWays to improve bottleneck

capacitycapacity

a.a. Put an extra work stationPut an extra work station

it will causeit will cause smvsmv to be half andto be half anddouble the capacitydouble the capacity

b.b. Distribute the excess work to theDistribute the excess work to theother work stations(it is being appliedother work stations(it is being appliedcurrently)currently)


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Distributing the excess work toDistributing the excess work to

other work stations in the lineother work stations in the line Required capacity = 69 units per hourRequired capacity = 69 units per hour

Current production = 45 units per hourCurrent production = 45 units per hour

Work remained= 69Work remained= 69--45= 24 units per hour45= 24 units per hour extra time required= 24*1.145*1.15=extra time required= 24*1.145*1.15=

31.6 minutes = 31 minutes 36 seconds31.6 minutes = 31 minutes 36 seconds

Looking at the operation flow chart for the workLooking at the operation flow chart for the workstation having operation running at over capacitystation having operation running at over capacity

Band hem is that operationBand hem is that operation

capacity= 315 units per hourcapacity= 315 units per hour


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Distribution of work .Distribution of work .

Band hemBand hem Minimum required units to be produced= 85 unitsMinimum required units to be produced= 85 units

per hourper hour

time required to do band hem operation on 85time required to do band hem operation on 85units= (1/315)*85= 0.27 hours = 16.19 minutesunits= (1/315)*85= 0.27 hours = 16.19 minutes= 16 minutes 11.4 seconds= 16 minutes 11.4 secondsextra time available = 43 minutes 48.6 secondsextra time available = 43 minutes 48.6 seconds

For cuff attach we require 31 minutes 36 secondsFor cuff attach we require 31 minutes 36 secondsSo we can accommodate it hereSo we can accommodate it here

still time available = 12 minutes 12.5 secondsstill time available = 12 minutes 12.5 seconds


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Search for next bottleneckSearch for next bottleneck

Cuff run is the next operation having least capacityCuff run is the next operation having least capacity

But it cant be said as a bottleneck operationBut it cant be said as a bottleneck operationbecause it doesnt lie on the critical pathbecause it doesnt lie on the critical path

The sub path is having lead of 4.412 minutes overThe sub path is having lead of 4.412 minutes overits counter path on the junction operationits counter path on the junction operation

So the delay caused by the cuff run operation willSo the delay caused by the cuff run operation willbe compensated by the lead timebe compensated by the lead time


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Operation = cuff runOperation = cuff run




top

Collarinspection

Plackettrim

Frontplacket

Frontbutton hole

Pocketattach

Pocketiron

Pocketiron & trim

Pockethem


Shoulderjoint

Sleeveplacket

SleeveBartac

Sleeve boxSleeve

button hole


Cuff top

Collar attach

Collar finishing

Sleeve attach

Sleeve top

Side seam


Checking &trimming

Front

buttonattach

Buttonmarking

Collar &

cuff buttonhole

Bottomhem Cuff attach

Leastcapacity

= 51uphsmv=1.0

1 mSub path viacuff run is

having leadtime = 4.412m over its

counter path

Frontpairing

Buttonplacket


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Search for the nextSearch for the nextbottleneckbottleneck

Sleeve topSleeve top Capacity=58 units per hourCapacity=58 units per hour

SMV= 0.88 minutesSMV= 0.88 minutes

Extra units to beExtra units to be operationalisedoperationalised = 11 units per hour= 11 units per hour

Time required to do sleeve top operation on 11 units =Time required to do sleeve top operation on 11 units =11*0.88*1.15 = 11 minutes 8 seconds11*0.88*1.15 = 11 minutes 8 seconds

3 options3 options

We can accommodate it on the work station at whichWe can accommodate it on the work station at which

band hem is being doneband hem is being done Put an extra work stationPut an extra work station

Search for another work station which is running onSearch for another work station which is running onover capacityover capacity


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Search for the work stationSearch for the work station

running at over capacityrunning at over capacity Main label attachmentMain label attachment

Capacity = 206 units per hourCapacity = 206 units per hour

SMV= 0.26 minutesSMV= 0.26 minutes Required capacity = 142 units per hourRequired capacity = 142 units per hour

Time require for 142 unit = 142*1.15*0.26= 41Time require for 142 unit = 142*1.15*0.26= 41minutes 38.4 secondsminutes 38.4 seconds

Extra time available= 19 minutes 21.6 secondsExtra time available= 19 minutes 21.6 seconds So we can accommodate the 11 units per hour forSo we can accommodate the 11 units per hour for

the sleeve top operationthe sleeve top operation

Still the time available = 8 minutes 13 secondsStill the time available = 8 minutes 13 seconds


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Improvement in the lineImprovement in the linecapacitycapacity

Current capacity = 550 units per shiftCurrent capacity = 550 units per shift

Projected improvement=10% or 56 unitsProjected improvement=10% or 56 units

per shiftper shift New projected capacity = 606 units perNew projected capacity = 606 units per

shiftshift

Per hour capacity = 76 unitsPer hour capacity = 76 units

So the bottleneck operation will be theSo the bottleneck operation will be theoperation running on the capacity less thanoperation running on the capacity less than

76 units per hour76 units per hour


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Critical path length= 10.017Critical path length= 10.017minutesminutes




top

Collarinspection

Plackettrim

Frontplacket

Frontbutton hole

Pocketattach

Pocketiron

Pocketiron & trim

Pockethem


Shoulderjoint

Sleeveplacket

SleeveBartac

Sleeve boxSleeve

button hole


Cuff top

Collar attach

Collar finishing

Sleeve attach

Sleeve top

Side seam


Checking &trimming

Front

buttonattach

Buttonmarking

Collar &

cuff buttonhole

Bottomhem Cuff attach

Frontpairing

Buttonplacket


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Operations with capacity


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batch flow process

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