Mixed Model Map Workbench Calculations

Mixed Model Map Workbench Calculations

Mixed Model Map Workbench uses the following calculations:

Calculate

The Calculate function on the Mixed Model Map Workbench performs calculations using parameters specified for a plan. Calculate options include:

• No IPK

  Resource requirements are calculated using the IPK value as zero on the line operation.

  IPK Needed = 0

  Resource Needed per operation

  = Weighted Resource Usage

  divided by Operation TAKT for the operation

• Based on One Resource

  The IPK needed on the line operation is calculated assuming one resource at each operation.

  Resource Needed per operation = 1

  

• Based on Assigned IPK

  Resources are calculated using the Assigned IPK at the line operation.

  IPK Needed for the operation = IPK assigned or the operation

  Resource Needed at each line operation

  

• Based on Assigned Resource

  The IPK Needed on the line operation is calculated using all the Assigned resources.

  IPK Needed for the operation

  

  Resource needed calculation:

  

Average Daily Demand Calculation

Total Demand multiplied by (1 + Boost %

Divided by Demand Days

Line TAKT

Rate the line produces one item to fulfill demands:

Working Hours Per Day (per line)

divided by Average Daily Demand for the item.

Operation TAKT

Rate the operation produces one item to fulfill operation demands. A single line can be used to manufacture multiple items, different items can have different routings, and some operations might be unique for a particular item.

Operation TAKT

= Working Hours per day for the line

divided by the item Process Volume

Process Volume

The number of items an operation produces in manufacturing day. A single operation can be used to manufacture multiple items, different items can use different routings, and some operations might be unique for a particular item. Process Volume is not effected by Assigned Resources and IPK.

Process volume

= Average Daily Demand for the item

multiplied by Net Planning Percent for the operation

divided by Reverse Cumulative Yield for the operation

Machine, Labor, Elapsed, Weighted Time

This includes:

• Total Machine Resources usage time in an operation

• Total Labor Resources usage time in an operation

• Total Machine and Labor Resources usage time in an operation

• Weighted Time is the weighted average usage time across all items produced in a line.

Machine, Labor, Elapsed, and Weighted Time are not effected by Assigned Resources, only usages are considered.

Usage, IPK, Assigned Example

For example:

Usage is 1

Assigned is 0.5, and the calculation is based on Assigned Resources

IPK is used to fulfill the required resource

The outputs will then be used by the next operation to keep the line flowing.

If the IPK is 20, 20 extra components are needed at the end of the resource per day, to keep the line flowing

See: In Process Kanban Assignment

Takt Time for Assigned

Takt time for assigned is the time per unit that each operation will achieve given the number of resources assigned. (Also called the Operational Cycle Time.)

Takt Time for Assigned is calculated using the following formula:

Machine Weighted Time / Machines Assigned

If machines assigned is equal to 0, then takt time for assigned is 0.

Operation TAKT As Assigned

Example 1:

Operation TAKT is 15 minutes

Usage is 1, Assigned is 2

Resource TAKT is 7.5 minutes

The work can be completed 2 times faster, that is—15 divided by 2 = 7.5 minutes

Example 2:

If Operation TAKT is 15 minutes

Usage is 2, Assigned is 3

Resource TAKT is 10 minutes

The work can be finished 3/2 times faster, that is—15 divided by (3/2) = 10 minutes

Line TAKT As Assigned

The ratio of Line TAKT As Assigned, and Line TAKT, is the maximum ratio of the Operation TAKT As Assigned and Operation TAKT in the line.

• When Operation TAKT As Assigned is greater than Operation TAKT, the current setup results in slower time to complete the operation.

• When Operation TAKT As Assigned is less than Operation TAKT, the current setup results in faster time to complete operation.

Color Representation on the Mixed Model Map Workbench

Lines

Line TAKT As Assigned

• Red—Resource overcapacity or IPK overcapacity is greater than 0

• Yellow—Line TAKT As Assigned is greater than Line TAKT

Operations

Operation, Operation TAKT As Assigned

• Red—Resource overcapacity or IPK overcapacity is greater than 0

• Yellow—Operation TAKT As Assigned is greater than Operation TAKT

Operation Detail

Resource, Usage, Needed, IPK Needed

• Red—IPK Needed is greater than IPK Assigned

• Yellow—IPK Needed is greater than 0, and Maximum Resource Needed or Assigned is less than Usage

Resources

Resource, Needed, Relocation Needed

• Red—Resource Needed is greater than Resource Assigned

• Yellow—Relocation Needed = Yes

Resource Detail

Line, Operation, Resource Needed, IPK Needed

• Red—Resource Needed is greater than Resource Assigned

• Red—IPK Needed is greater than IPK Assigned

Resource Assignments

Department, Unit, Total Unit

• Red—Unit is less than Assigned

• Red—Total Units is greater than Total Assigned

Percentage Needed

The percentage difference between Assigned and Needed based on the Needed value:

Assigned subtracted by Needed divided by Needed multiplied by 100

• Green—resource is overassigned

• Red—resource is underassigned

Percentage Assigned

The percentage difference between Needed and Assigned based on the Assigned value:

Needed subtracted by Assigned divided by Assigned multiplied by 100

• Green—resource is overassigned

• Red—resource is underassigned

Percentage number 999 signifies a value is zero or null.

Absolute Value

Needed (blue) and Assigned (green) values are displayed next to each other for comparison.