Lecture about Production FLow
Lecture Objectives
1. Bottlenecks in Production systems:
- Explain the concept of bottlenecks.
- Understand their causes and effects on system capacity.
2. Line Balancing:
- Theory and practical examples.
- Understand system losses and balancing losses.
- Learn to calculate balancing losses and understand why they occur.
Important Concepts
1. Bottleneck Analysis
Definition: A bottleneck limits the production system's capacity; production cannot exceed the bottleneck's rate.
2. Theory of Constraints (TOC)
Steps:
- Identify the bottlenecks or system constraint.
- Exploit the bottleneck by maximizing its efficiency.
- Subordinate other processes to the bottleneck.
- Elevate the bottleneck by improving its capacity.
- Repeat the process for continuous improvement
I am not finished with this "tråd" will continue tomorrow.
Because I can't continue editing the question so I will continue here:
More important concept in the lecture of "Production Flow" is:
3. Line Balancing
Definition: Distribute work evenly across workstations to match the TAKT time (time available per unit produced).
Balancing Losses:
- Occur when stations are not fully utilized.
- Lead to idle time and inefficiency.
Cycle time: Time required to complete all tasks at a workstation.
Goal with Line balancing is to achieve high production capacity, short lead times, and high-quality output.
4. Losses in Production
Types of Losses:
- Cycle time Variation: Differences in task times across products.
- Setup Times: Time spent adjusting machines for new products.
- Short Stoppages: Easily fixable delays by operators.
- Breakdown: Significant delays requiring specialized repair.
5. Downtime
Metrics: Mean time to repair (MTTR), Mean time to failure (MTTF), Mean Downtime (MDT).
Components: Waiting Time (WT), Repair Time (TTR).
6. Idling and Blocking
Idling: When a machine waits for input due to upstream delays.
Blocking: When output cannot be transferred because downstream systems are full.
Solution: Add buffers to minimize idle time and maintain smooth flow.
7. Productivity
Definition: Ratio of output to input. Improving this increases efficiency and reduces waste.
8. Sustainable Production systems
Utilize virtual tool to enhance performance and circularity using economic, environmental, and social KPIs.
9. Simulation for Bottleneck Analysis
Use buffer levels, queue sizes, and utilization diagrams to identify bottlenecks in virtual models.
