Professional Documents
Culture Documents
Ron Lembke
Operations
Belt Conveyor
PRECEDENCE DIAGRAM
Draw precedence graph
(times in minutes)
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LEGAL ARRANGEMENTS
A B
5 G
20 15
E I J
C D 8 7
H 12
5 10 F 12
3
Ok: AC|BD|EG|FH|IJ
ABG|CDE|FHI|J C|ADB|FG|EHI|J
NOT ok: BAG|DCH|EFJ|I
DAC|HFE|GBJ|I
LEGAL ARRANGEMENTS
A B CT = maximum of workstation times
5 G
20 15
E I J
C D 8 7
H 12
5 10 F 12
3
AC|BD|EG|FH|IJ = max(25,15,23,15,19) = 25
ABG|CDE|FHI|J= max(40,23,27,7) = 40
C|ADB|FG|EHI|J = max(5,35,18,32,7) = 35
AC BD EG FH IJ
CYCLE TIME
The more units you want to produce per hour, the less time a part
can spend at each station.
Cycle time = time spent at each spot
Nodes # after
Choose C first, then, if possible,
C 6 add D to it, then A, if possible.
D 5
A 4
B,E,F 3
A B G
G,H 2 20
5
15
I 1 E I J
C D 8
H 12 7
5 10 F 12
3
PRECEDENCE DIAGRAM
Draw precedence graph
(times in seconds)
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
NUMBER OF FOLLOWING TASKS
Nodes # A could not be added to first
station, so a new station must be
after created with A.
A 4
B, E, F all have 3 stations after,
B,E,F 3 so use tiebreaker rule: time.
G,H 2 B=5
E=8
I 1 F=3
Use E, then B, then F.
A B
5 G
20 15
E I J
C D 8 7
H 12
5 10 F 12
3
PRECEDENCE DIAGRAM
E cannot be added to A, but E can be added to
C&D.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
PRECEDENCE DIAGRAM
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
PRECEDENCE DIAGRAM
Next priority B can be added to A.
Next priority F can’t be added to either.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
NUMBER OF FOLLOWING TASKS
Nodes #
after G and H tie on number coming after.
G,H 2 G takes 15, H is 12, so G goes first.
I 1
PRECEDENCE DIAGRAM
G can be added to F.
H cannot be added.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
PRECEDENCE DIAGRAM
I is next, and can be added to H, but J cannot
be added also.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
PRECEDENCE REQUIREMENTS
A B
5 G
20
15
E I J
C D 8
7
H 12
5 10 F 12
3
Why not put J with F&G?
AB CDE HI
FG J
CALCULATE EFFICIENCY
We know that at least 4 workstations will be needed.
We needed 5.
Sum of task times (T)
Efficiencyt =
Actual # WS * Cycle Time
= 97 / ( 5 * 25 ) = 0.776
We are paying for 125 minutes of work, where it only
takes 97.
LONGEST FIRST
Try choosing longest activities first.
A is first, then G, which can’t be added to A.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST
H and I both take 12, but H has more coming
after it, then add I.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST
D is next. We could combine it with G, which we’ll do later. E is next, so for now
combine D&E, but we could have combined E&G. We’ll also try that later.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST
A B
5 G
20
15
E I J
C D 8
12 7
H
5 10 F 12
3
CT = 25, so efficiency is again
Eff = 97/(5*25) = 0.776
LONGEST FIRST- COMBINE E&G
Go back and try combining G and E instead
of D and E.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST- COMBINE E&G
J is next, all alone. C is added to D, and B is
added to A.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST- COMBINE E&G
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST - COMBINE D&G
Back up and combine D&G. No precedence violation.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST - COMBINE D&G
Unhook H&I so J isn’t stranded again, I&J is 19, that’s better than 7.
E&H get us to 20. This is feeling better, maybe?
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
LONGEST FIRST - COMBINE D&G
5 Again! CT is again 25, so efficiency is again 97/(5*25) = 0.776
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
CAN WE DO BETTER?
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
CAN WE DO BETTER?
If we have to use 5 stations, we can get a
solution with CT = 20.
B
A 5 G
20
15
E I J
C D
8
12 7
H
5 10 F 12
3
CALCULATE EFFICIENCY
With 5 WS at CT = 20
Sum of task times (T)
Efficiencyt =
Actual # WS * Cycle Time
= 97 / ( 5 * 20 ) = 0.97
We are paying for 100 minutes of work, where it
only takes 97.
OUTPUT AND LABOR COSTS
With 20 min CT, and 800 minute workday
Output = 800 min / 20 min/unit = 40 units
Don’t need to work 800 min
Goal 32 units: 32 * 20 = 640 min/day
5 workers * 640 min = 3,200 labor min.
We were trying to achieve
4 stations * 800 min = 3,200 labor min.
Same labor cost, but more workers on shorter
workday
HANDLING LONG TASKS
Long tasks make it hard to get efficient
combinations.
Consider splitting tasks, if physically possible.
If not:
Parallel workstations
use skilled (faster) worker to speed up
SUMMARY
Compute desired cycle time, based on Market
Demand, and total time of work needed
Methods to use:
Largest first, most following steps, trial and error
Compute efficiency of solutions
A shorter CT can sometimes lead to greater
efficiencies
Changing CT affected length of work day, looked at
labor costs