Process Flow & Analysis contd.

-
 Career Choice:
Engineering/ Management ..
.. Career Choice
 Flow Time
(FT)

In queue In
service
 .. Metrics (contd.) ..
• Velocity Ratio = Value-Add Time ÷ Flow Time
– How productively the customer’s (or material’s) time
in the system is spent

• Utilization = Actual Usage Time ÷ Available

Time
– How much of the resource’s time is actually used on
productive work (can also be stated in terms of
output)

• Reliability: The probability of performing the

required function at specified service level in a
given environment for a specified period ^
 .. Metrics (contd.)
• Availability: Proportion of time for which the
resource is up and available for use ^

• Efficiency = Actual Output ÷ Standard Output

• Yield = Good Output ÷ Total Output

– Proportion of units coming out right (in all or?)

Overall Equipment Effectiveness (OEE) =

Availability × Efficiency × Yield
Process Flow Analysis with
Bottleneck (Situation I)
 Flow Analysis Example ..
► Standard process for cleaning teeth
► Cleaning and examining X-rays can happen
simultaneously
► All possible paths must be compared

4 Cleaning

2 X-Ray 3 X-ray 24 min/unit 6 Check

1 Checkin 5 Dentist
(take) (develop) out

2 min/unit 2 min/unit 4 min/unit 4 X-ray 8 min/unit 6 min/unit

exam

5 min/unit
.. Flow Analysis 1 Check
in
2 X-ray
(take)
3 X-ray
(develop)
4 Cleaning

24 min/unit 5 Dentist
6 Check
out

Example 2 min/unit 2 min/unit 4 min/unit 4 X-ray

exam
8 min/unit 6 min/unit

5 min/unit
.. Flow Analysis 1 Check
in
2 X-ray
(take)
3 X-ray
(develop)
4 Cleaning

24 min/unit 5 Dentist
6 Check
out

Example 2 min/unit 2 min/unit 4 min/unit 4 X-ray

exam
8 min/unit 6 min/unit

5 min/unit

Enter Cleaning Exit Exit at end

Cleaning
1st patient 8 min 32 min 46 min Final exit 14 min
(2+2+4 min) (8+24 min) (32+14 min) after Cleaning exit

2nd 32 min 56 min 70 min

patient (only one patient in
Cleaning at a time)

3rd patient 56 min 80 min 94 min

4th patient 80 min 104 min 118 min
Cycle repeats every 24 minutes
.. Flow Analysis 1 Check
in
2 X-ray
(take)
3 X-ray
(develop)
4 Cleaning

24 min/unit 5 Dentist
6 Check
out

Example .. 2 min/unit 2 min/unit 4 min/unit 4 X-ray

exam
8 min/unit 6 min/unit

5 min/unit

► Bottleneck is the hygienist at 24 minutes

► Hourly capacity is 60 ÷ 24 = 2.5 patients per hour
► X-ray exam path is 2 + 2 + 4 + 5 + 8 + 6 = 27 minutes
► Cleaning path is 2 + 2 + 4 + 24 + 8 + 6 = 46 minutes
► Longest path involves the hygienist cleaning the
teeth, patient could complete in 46 minutes
[excludes waiting times and other imperfections]
 Flow Analysis Example (modified)
► Modified process for cleaning teeth
► Cleaning can happen simultaneously along with
developing + examining X-rays
► All possible paths must still be compared

4 Cleaning

2 X-ray 24 min/unit 6 Check

1 Checkin 5 Dentist
(take) out

2 min/unit 2 min/unit 3 X-ray 4 X-ray 8 min/unit 6 min/unit

(develop) exam

4 min/unit 5 min/unit
.. Flow Analysis
Example
(modified)
.. Flow Analysis
Example
(modified)
Enter Cleaning Exit Exit at end
Cleaning
1st patient 4 min 28 min 42 min Final exit 14 min
(2+2 min) (4+24 min) (28+14 min) after Cleaning exit

2nd 28 min 52 min 66 min

patient (only one patient in
Cleaning at a time)

3rd patient 52 min 76 min 90 min

4th patient 76 min 100 min 114 min
Cycle repeats every 24 minutes,
i.e. same throughput rate but shorter flow time.
.. Flow Analysis
Example ..

► Bottleneck is still the hygienist at 24 minutes

► Hourly capacity is still 60 ÷ 24 = 2.5 patients per hour
► X-ray exam path is 2 + 2 + 4 + 5 + 8 + 6 = 27 minutes
► Cleaning path is 2 + 2 + 24 + 8 + 6 = 42 minutes
► Longest path involves the hygienist cleaning the
teeth, patient could complete in 42 minutes
[excludes waiting times and other imperfections]
Reliability & Availability

Supplement to Text Ch. 4

 Reliability
• Need to be defined at element level as well as
system level

• Overall System Reliability (R) =

Function of Individual element reliabilities (Ri) &
System structure
 Computing Reliability ..

Components in series

0.90 0.80 0.90 x 0.80 = 0.72

R1 R2

For a 2 element series system: R = (R1) (R2)

In general, for an ‘n’ element series system:

R = (R1) (R2) … (Rn) Example in
Text p. 175
 .. Computing Reliability ..
Components in parallel

0.80
R2
0.90 + (1-0.90) x 0.80 = 0.98
Or
0.90 1 - [(1-0.90) x (1-0.80)] =0.98
R1

For a 2 element parallel system:

R = (R1) + (1-R1)(R2)
or
= 1 – [(1-R1)(1-R2)] Example in
Text p. 175
 .. Computing Reliability
Components in parallel

0.70
R3

0.80 1 - [(1-0.90) x (1-0.80) x

R2 (1-0.70)] = 0.994

0.90
0.90
R1

In general, for an ‘n’ element parallel system

Example in
R = 1 – [(1-R1) (1-R2) … (1-Rn)] Text p. 175-
176
Overall (Hybrid) System Reliability

0.90 0.92

0.98 0.90 0.95

0.95+0.92
0.98 0.90+0.90(1-0.90)
(1-0.95)

0.98 x 0.99 x 0.996 = 0.951 Example in

Text p. 176
 System Availability (SA)

Text
Example situation: p. 180
Choosing a service provider from multiple
candidates based on Availability, when MTBF and
MTTR are stated, and all other factors are ‘equal’.
System Availability example

PROVIDER MTBF (HRS) MTTR (HRS)

A 60 4.0
B 36 2.0
C 24 1.0

Different example
from Text p.180-181
System Availability example

PROVIDER MTBF (HRS) MTTR (HRS)

A 60 4.0
B 36 2.0
C 24 1.0

SAA = 60 / (60 + 4) = .9375 ≈ 94%

SAB = 36 / (36 + 2) = .9473 ≈ 95%
SAC = 24 / (24 + 1) = .96 = 96%

Different example
from Text p.180-181
 Improving System Availability
• Improve reliability and maintainability at element
level

• Proper operating conditions, regular maintenance,

proper spare part availability ..

• Modify system structure through:

– Decoupling (e.g. buffers)
– Introducing redundancy (“Hot” or “Cold” standby)

• Trade-off: Cost of redundancy/ decoupling vs.

Cost or Probability of system failure