Useful IE Formulas for workplace

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productivity enhancementakar
b ub am
A
r . M. n Akr
: E ng Arfa
n by r: Sir
r itte eade
W of r
Pro
Context list
 Relaxed Single cycle time
 Cycle time
 Average single cycle time
 Rating
 Clock time
 On-standard time
 Off-standard time
 Efficiency
 Takt time/Production rate ar
a k
 Throughput time/Flow rate b ub am
A
 Overall equipment effectiveness r . M. n Akr
 Man to machine ratio : E ng Arfa
n by r: Sir
 Capacity r itte eade
 Target W of r
P ro
 Earned Mints/SAM Produced
Context list
 No. of machines Required
 Variance %age
 Work in process
 Lead time
 Machine utilization
 Performance
 Difference between performance and efficiency
 Line balancing ratio
 Yamazumi chart a k ar
 Labor cost per mints b ub am
A
r . M. n Akr
 Cost per mints
: E ng Arfa
 Piece rate n by r: Sir
r i t te ade
 Changeover time W of re
 Changeover process time Pro
What is industrial Engineering?
It is engineering to do things in a better way
Another Definition:
industrial engineering is a field that is used to
1- To Reduce cost
2- To Increase productivity
3- Utilizing Available Resources or Min resources if needed

Role of Industrial engineering in industry:

1- Layout Design 13-Wages Calculation or Better Payment system

2- Line balancing 14-M/Cs Requirement
3- Productivity improvement 15-Incentive Planning a k ar
4-Lead time calculation 16-Skill Matrix b ub am
A
5-Material consumption 17-Method document r . M. n Akr
: E ng Arfa
6-Operation Breakdown by r: Sir
18-Standardization
n
7-SAM Sheet Development itte eprevention
19-Failure
r a de
8-Work study W of r
20-Production scheduling
9-Control on Manufacturing Cost Pro
10-KPI’s Making and Follow-up
11-Quality Management
12-Waste Calculation and Control
Benefits of Industrial Engineering:
1- standardization
2-Production scheduling
3-Cost Saving Project
4-Productivity Improvement
5-Better Payment system
Techniques of Industrial engineering:
1- Method Study
2-Time Study
3-Capacity Study
4-Follow-up Studies
5-Layout Planes
6-Training
7- Statistical Quality Control
a k ar
8- Scheduling Study b ub am
A
Major Floor Activities: r . M. n Akr
1- Line Balancing 6-Target setting: E ng Arfa
2-Bottleneck Removing 7-New n by aid
work r : S r
idesigning and setting of
t t e d e
3-Layout Setting ri reawork aids
Wrunning f
oRate
4- SAM Calculation 8-Pc
P r o calculation.
No. of M/c s planning 9-Efficiency Monitoring.
5-Down time monitoring. 10-OB Development
11-Changeover studies. 12-Method documents Providing.
SOME BASIC IE CALCULATION
What is cycle time?
“The time required to complete a Function, Job or task” or another definition is

“It is repeatable time in which one product can be produced”

e.g.)- if a product take 15 sec to complete then its cycle time will be 15 Sec
Average Single Cycle Time =Sum of Cycle Times/No of cycle time
e.g.) Observed time = 20,22,21,19,21
A.S.C.T =20+22+21+19+21/5
= 20.6 sec
Relax Single Cycle Time = Single Cycle Time x (1+allowances).
e.g.)
Single Cycle Time / Pcs = 15 sec
a k ar
Personal Fatigue = 10% b ub am
A
M/c Allowance = 7.5 % r . M. n Akr
Total Allowance = 10 % + 7.5 % : E ng Arfa
n by r: Sir
= 17.5 %
r itte eade
W of r
Relax Single Cycle Time = Single Cycle Time x (1+allowances)
=15 x (1 + 0.175) Pro
=17.625 sec
= 0.28 + 0.625/60
=0.28 + 0.0104
=0.2904 Min
Rating is the assessment of the worker’s rate of working relative to the observer's
concept of the rate corresponding to standard pace.
Standard pace or standard performance is the rate of output which Qualified workers will
achieve naturally without exhausted as an average over the working day or shift. This
performance is denoted as 100.
So
SAM =BM x (1 + allowances) + 0.03
e.g.) C.T = 20+22+21+19+21
= 20+22+21+19+21/5
A.S.C.T= 20.6 sec
= 0.3433 min
e.g.) rating of our operator is 90 %
SAM = 20.6 x 0.90 x ( 1+0.5) + 0.03 min a k ar
= 21.321 s + 0.03 min b ub am
A
= 0.355 min + 0.03 min r . M. n Akr
: E ng Arfa
= 0.385 min
n by r: Sir
= 23.121 sec itte de
Wr of rea
Pro
Clock time = on – standard time + off – standard time
Off – standard time = Break time + tea time etc. Let
On – standard time = clock time - off-standard time SAM = 7.2
Efficiency = output / input x 100 output = 1400
= (SAM x Output)/ (DL x clock time) x100 DL = 28
= (7.2 x 1400)/ (28 x 480) x 100
= 10080/13440 x100
= 75
Takt time/production rate
= Total available production time / customer demand
e.g.) Per day target / customer demand = 1400 pcs
Shift time = 480
Takt time = 480/1400
= 0.34 min
a k ar
ub am
= 20.6 sec Ab
r . M. n Akr
: E ng Arfa
n by r: Sir
r itte eade
W of r
Pro
Throughput time :-
Amount of time required by a product to pass through the whole
Manufacturing process.
(Process time + inspection time + Movement time +waiting time)
Through Time = completion of last operation time – induction time for first operation
Product last operation time =12:06pm min
Product induction time =11:30am
=12:06 -11:30 =36 min .
Over all equipment effectiveness [OEE]
OEE- Availability x Performance x Quality
=clock time – loss time – break /clock time x min produced / Available time x good pcs / Total
pcs
a k ar
= 480-60-30/ x 320/390x 290/300
b ub am
A
=390//480x82.05%x96%
r . M. n Akr
=0.8125x0.8205x0.96x100 : E ng Arfa
=63.99% n by r: Sir
e
itt eade
r
W of r
Pro
MAN TO MACHINE Ration [MMR]
MMR = available work force / No. of M/Cs
Available work force =1000
M/Cs =700
MMR =1000/700
MMR=1.42
CAPACITY
Refers to what a person can do in standard condition .
Capacity =shift time /RSC
=480/0.2904 [as value given value on pervious page
Capacity=1653

a k ar
b ub am
A
r . M. n Akr
: E ng Arfa
n by r: Sir
r itte eade
W of r
Pro
Target
Clock time x of M/Cs in line /SAM
=480x28/7.4=13440/7.4=1816
Line target =1816 pcs
Operation target = clock time / SAM of given operation
=480/0.25
=1920
Earned mints /SAM products
=Total production x SAM
Total production =1400
SAM=2.9
SAM production =1400x2.9=4060mnts
a k ar
M/Cs required
b ub am
A
=SAM x target /clock time planed efficiency of M/Cs
r . M. n Akr
SAM =7.4 : E ng Arfa
Target =1400 n by r: Sir
r i t te ade
Clock time =480 W of re
Planned efficiency of M/Cs= 80% Pro
=7. 4x 1400/480x 0.80=10360/384 =27.M/Cs
Variance %age / variance
variance =line capacity –line target
line capacity =1600
line target =1200
variance =16000-1200
=400
variance % age = capacity –target /capacity x100
Capacity =1600
Line target =1200
=[1600-1200/1600x 100
=25%
WIP [work In process
a k ar
=Total WIP [pcs] in whole value stream /Avg . store receiving per daybu. b am
M .A Akr
Total WIP pcs =145,000
n g r. fan
Avg /store receiving =6,000 y : E r Ar
n b r: Si
=145000/6000 e
itt eade
=24.16days WIP available r
W of r
Lead-time Pro
Total time required from ratio material induction till finished goods completion.
M/C utilization
= on –standard time /clock time x 100
On standard time = 480 -60 -15 [prayer time
= 405
= 405/ 480 x 100
=84.375%
Performance Refers to what a person actually does in his/her daily routine .
Performance = SAM x out put /DL x on standard time x100
SAM =7.4
On standard time =405
Out put =1000
DL/ Total of M/Cr word =21
a k ar
=7.4x1000/21x405x100
b ub am
A
=87% .M
. Akr
r fan
n g
E r Ar
y :
b r: Si
e n
r itt eade
W of r
Pro
Difference between performance & efficiency
Efficiency measures on clock time /shift time while performance measures on
on-standard time
Line balancing Ratio
=Total cycle time /No.of operation x bottleneck cycle time
Total c.t=7.4
Of operation =24
Bottleneck cycle time =0.5
=7.4 /24 0.5 x100
LBR %=61.6%

YAMAZUMI CHART
It is a line balancing tool
A graphical tool to represent each individual operation cycle time and
a k ar
its gap from takt time b ub am
. A kr
Quick to highlight bottleneck and under utilized workstation this r . Mhighlight
A
E n g rfan
the variation in terms of inventories and waiting time
b y: Sir A
This help to identify these variations with and goal ioft n er: it to manage
ereducing
r t a d
the flow production W of r e
Pro in a month / Total Sam production by
Labor cost per minute =Total salary of the operators
operator
= 255500/ 0.40 x 2000x26
LCPM =1.225
Quota =clock Time/SAM
e.g. = 480/0.28=1714.285
Piece rate =target wages /quota Target wages =25500of working days 26
= 981/1714 =255500/26
Pc rate =0.572 =981

Change over time

last pc out put time of running Article first pcs output time of new of article
Change over Process Time
Total time required from first pc induction to first pc output .

a k ar
b ub am
A
r . M. n Akr
: E ng Arfa
n by r: Sir
r itte eade
W of r
Pro
 a k ar
b ub am
A
r . M. n Akr
: E ng Arfa
n by r: Sir
r itte eade
W of r
Pro