Lean total cycle time

Caveat:   Blitzes are all too often un-targeted, .  done with little concern as to the overall impact on the total company.   The results of such un-focused blitzes typically have a significant local impact, microcosms of excellence , but little or no impact on overall company well being.   See “Solutions Looking for a Problem” below.

  • Blow-Through BOM’s (Bills of Material):   Many “assembled product” manufacturers need to maintain subassembly identity, and/or control configuration, for replacement parts.   In these circumstances, rather than have a flat bill of material, it is much more practical to continue to show all subassembly levels on the bill of material. A “Blow Through” level, allows the subassembly’s parts to be called out, for kitting or backflush purposes, on the next higher level assembly.   The MRP algorithm “blows through” .  treats the subassembly’s parts as if they were called out on the next higher-level assembly.
  • Boom-Bust Cycle:   Some Causes:   I just got off the phone with a steel finishing plant / distributor.   He said that their on-time delivery performance was terrible, and that their lead times had extended considerably.   When I mentioned some ways to fix this issue, his response was classic:   “The customers have learned to expect it”   “We can’t turn down orders.   We just promise what they want to hear, then beg forgiveness.” And what do the customers do in these situations?   You’ve go it!   They double order.   They order high “just in case”.   They ask for it early, knowing full well that it will be late.

    I am working on implementing OEE in one of our machines that makes centertubes for automotive oil filters. The steel is rolled and each part number has specific diameter and length. However, the run-rates vary for each part numbers. I am somewhat able to calculate Takt time for each part number based on the standard run-rate. However, the problem for me is to determine Ideal Cycle Time. The machine can run as fast as 65 PPM for one part number while it runs as slow as 13 PPM for some other part number. In this case, what would be the optimal way to calculate Ideal Cycle Time for each part numbers? As you know, Ideal Cycle time is required to calculate Performance Metric of OEE.

    If cycle times vary widely, whether from cycle to cycle, or from person to person, it is an indication that there is something wrong with the process. On occasion, you will have one person who can’t seem to keep up. Make sure you observe the operator before you to jump to conclusions. In all likelihood, the person is slower because he is not following the process, not because he can’t do the work. In most cases, this is a training problem, meaning the operator doesn’t know the right way. That’s not the operator’s fault. It’s yours. 

    Cycle time is the time it take to complete your task or piece of the process (washing, loading or drying).
    Takt time is the pace at which you need to produce to meet customer demand. It is available working time divided by customer demand in that period of time. Say if you have 5 working hours available to do laundry and you have 10 customers a day that need your services, your takt time is 5/10=. So you need to deliver a clean load every .5 hrs, or every 30 minutes. It is solely a calculated time based on your available working time and customer demand. It has nothing to do with your cycle time which is how long it takes you to perform a task.
    The time to wash might be 60 minutes or might be, 90 minutes. In which case you can use your cycle time to calculate how many machines you should have or people washing (if hand washing).
    In this case you would CALCULATE the number of resources you need:
    (cycle time) / (Takt time) = # of resources needed. In this case 60 / 30 = 2. So you would need 2 machines to meet your takt time.

    Lean total cycle time

    lean total cycle time

    Cycle time is the time it take to complete your task or piece of the process (washing, loading or drying).
    Takt time is the pace at which you need to produce to meet customer demand. It is available working time divided by customer demand in that period of time. Say if you have 5 working hours available to do laundry and you have 10 customers a day that need your services, your takt time is 5/10=. So you need to deliver a clean load every .5 hrs, or every 30 minutes. It is solely a calculated time based on your available working time and customer demand. It has nothing to do with your cycle time which is how long it takes you to perform a task.
    The time to wash might be 60 minutes or might be, 90 minutes. In which case you can use your cycle time to calculate how many machines you should have or people washing (if hand washing).
    In this case you would CALCULATE the number of resources you need:
    (cycle time) / (Takt time) = # of resources needed. In this case 60 / 30 = 2. So you would need 2 machines to meet your takt time.

    Media:

    lean total cycle timelean total cycle timelean total cycle timelean total cycle timelean total cycle time

http://buy-steroids.org