omis 430 test 3

design capacity

Maximum theoretical output possible

Effective capacity

Maximum realistic output possible, given system constraints.

two measures of effectiveness

efficiency and utilization

factors of effective capacity

system design, system operation, and external factors

factors related to system design

facilities, product/services, process factors

factors related to system operation

human factors and operational factors

external factors

supply chain and other factors

determining/forecasting capacity requirements

long-term, short-term, and calculation

developing capacity strategies

1. Design flexibility into systems
2. Take stage of life cycle into account
3. Systems approach
4. Remember Capacity increases in “chunks”
5. Identify optimal operating levels

Evaluating Capacity Alternatives

1. Economically feasible?
2. Lead time?
3. Operating and maintenance costs?
4. Skill or expertise available?

Challenges of Service Capacity Planning

1. Need to be near customer
2. can not store i.e. inventory services
3. demand can be volatile

simple alternative

i. Identify fixed cost (FC)
ii. Identify variable cost per unit (v)
iii. Identify revenue per unit (R)

complex alternative

The answer depends on which yields higher Total Profit for your expected volume of business.

process selection

deciding on a way “a product will be produced” or deciding on a way a “service will be provided.”

Buy VS Make:

a. Available capacity
b. Available expertise
c. Ability to produce quality
d. Demand fluctuations
e. Cost

types of processing

project, job-shop, batch, repetitive, & continuous

project processing

Very Low volume, Very High variety, Very high cost

job-shop processing

Low volume, High variety (customization), High Cost (ER)

batch processing

Moderate volume, Moderate variety. This is still costly.

repetitive processing

High volume, Low variety, Cost per unit reasonable

Continuous processing

Very High Volume, Very Low Variety, Low cost per unit

advantages of automation

- Highly uniform output (quality)
- No boredom or fatigue for worker
- No labor problems
- High rate of output

disadvantages of automation

- Costly
- Inflexibility
- Resistance from workers

NC/CNC Machines

Computerized Numerical Controlled machines can be used at lowest level of automation of the process.

Robots

Robotic units have arm, power supply, and controller

FMS

group of automated machines and automated material handling to produce a variety of similar products.

CIM

links a broad range of manufacturing activities through a computer with design, manufacturing, planning, sales

Automation and flexibility

Level of Automation in your process will determine how much flexibility your system will have to handle variety of jobs or products

layout

the arrangement of machines, equipment, people or facilities that we use to produce a product or provide a service.

import layout design

operating costs, long-term efficiency, utilization of space

redesign of layouts

Inefficient operations, Accidents and safety hazards, change design, change volume

types of layout

1. Product layout (product specific)
2. Process layout
3. Fixed Position layout
4. Combination layouts

product layout

Work is arranged in sequence on a line per required operations.
"High volume and no or low variety" situations.

advantage and disadvantages of product layout

- High rate of output
- Low (variable) cost per unit
- High equipment and labor utilization
- High susceptibility to shutdowns or breakdowns

process layouts

Locate departments/areas to minimize material handling costs; i.e. distances traveled by Customers, materials

advantage & disadvantage of process layout

- Not susceptible to breakdowns or shutdowns
- Lower emergency/maintenance costs
- Utilization is lower
- Material handling can be slow and inefficient
- Higher WIP inventories

cellular layouts

A special version of a combination layout that offers flexibility, efficiency and low unit production

Advantages of celluar layouts

- Lower labor costs
- Less material handling
- Reduced set-up time
- Faster throughput time

group technology

identifying items that have similar design, manufacturing or processing characteristics and grouping them into "Part Families."

computer software

1. CRAFT. 2. SPACECRAFT. 3. LayOPT. 4. CORELAP. 5. ALDEP

goal of line balancing

Minimize idle time, maximize utilization of equip and labor, and obtain smooth flow of work.

line balancing steps

a) Cycle Time necessary for a required rate of production (CT)
b) Minimum # of workstations required (n)
c) Assigning "m" tasks among these work stations to minimize Total Idle Time.

Job design

specifying contents and methods to complete tasks to produce a product or sservice

job design for quality of work life

Several considerations go into Job Design so that the job for an individual not only provides enhanced quality of work life and safety but also assures higher efficiency and utilization.

efficiency approach

emphasizes on maximizing output and improving efficiency through use of “Specialization,” specifically the Labor Specialization.

behavioral approach

"Psychological Considerations" and emphasizes on "Satisfying worker wants and needs," making their job desirable

Five common desirable characteristics of any job

Skill variety, job identity, significance, autonomy, and feedback

effect of labor specialization and worker dissatisfaction

“Behavioral Approach” also uses "Job Rotation," "Job Enlargement," "Job Enrichment." and Motivation can also be a key factor in many aspects of work life.

job rotation

employee rotates between 2-3 specialized jobs.

job enrichment

generally, adds planning and control to the job.

job enlargement

generally, adds additional tasks to current job.

self directed teams

These are the groups of employees empowered to make changes in their work processes together to reach a common goal for the organization such as "Best quality or highest safety, etc"

method analysis

“how the entire job is being done"

flow process chart

charts are constructed using symbols (Circle-inspection, Square-operation, Arrow -transportation, Triangle- storage and "D" for Delay) to show the movement of people and materials

Gang process chart

to study the activities of workers involved.

motion study

Goal is to eliminate unnecessary motions (motions used are called Therbligs) and to identify the best sequence of motions for maximum efficiency.

SIMO charts

to analyze motions of hands, arms, and body (Therbligs) at the workstation

Ergonomics

It involves maximizing the employee performance by matching the employees to the tasks based on their individual capabilities and differences

method of work measurement

stopwatch time study method, predetermined time standards, and work sampling method

standard time

is the Amount of time it should take a qualified worker to complete a specified task working at a normal speed using a specified method.

stopwatch time study

- The desired accuracy
- The desired confidence
- The variability of observed times in the initial sample

predetermined time standards

- Describe the manual job using Therbligs (by dividing the job into basic motions)
- Obtain the time for each Therblig (basic motion) from the MTM tables
- Add the time values to get the time standard for that job

Therbligs

There is a set of 17 basic fundamental motions