MODULE 1

Process Planning and Standard Time Calculation

Production System

Production system is a set of interacting subsystems with the purpose of transforming production inputs into production outputs.

Production System

Production System Parameter

• Production• Productivity• Efficiency• Effectiveness• Utilitie• Quality• Capacity

MRP II (Manufacturing Resource Planning)

Relationship Between MRP and MRP II

Just In Time (JIT)

• Just In Time is a production system or a modern fabrication management system developed by Japanese – American named Taichi Ohno of Toyota motor vehicles companies.

• JIT is a concept in which the raw materials used for production activity brought from the supplier of the material was right on time needed by the production process, so it will greatly save even eliminate the cost of inventory.

• The tool that is used in the JIT called Kanban

Kanban

• JIT production system using a flow of information in the form of a Kanban card-shaped or other equipment such as flags, lights, and others

7 types of waste

• Over production• Waiting• Transporting• Unnecessary process• Inventory• Unnecessary movement• Rejection

5 S

Bill Of Material (BOM)

• BOM (Bill of Material) is a list of the number of components, material and the ingredients

Operation Process Chart• Operation Process Chart is a chart performs the

process of raw material into a product which the operation steps and inspection belongs.

OPC

• The Benefit of OPC: To know the production costs and machineTo know raw material spent (efficiency

consideration in each step and inspection) A tool for layout and facilities design. A tool to diagnose work method. A tool for work experience

OPC sign

•Operation

•Inspection

•Storage

•Double Activities

Standard Time

• Standard time is the time needed by the worker on average to do the assignment without pressure in a workstation.

• Methods to calculating:a. Directly

b. Indirectly

Directly Methods

a. Stopwatch

The steps are:– Measure the initial time per activity – Uniformity test – Sufficiency test – Standard time decision

Directly Methods using Stopwatch

• Uniform Test

• Sufficiency test:

If N’>N, then need more data

Standard Time Calculation

pWsWn

NWs xi

)1( kWnWb

Calculate the cycle time (Ws)

Calculate the standard time(Wb)

Calculate the normal time (Wn)

Standard time calculation(notes)

= total measurements times

N = Number of measurements

P (adjustment factors) = 1+∑operator performance level

k = allowance

xi

Indirectly Calculation

a. Standard Time Data

Standard time data is an indirectly time measurement, by tables, curves and formulas gained by direct measurement. It is about the historical data of time needed. In addition, the standard time is known

b. Motion Time Data

It is different with company’s standard time which has been developed. Motion time data uses developed table by some institute