Mixed Model Map Workbench uses the following calculations:
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:
Total Demand multiplied by (1 + Boost %
Divided by Demand Days
Rate the line produces one item to fulfill demands:
Working Hours Per Day (per line)
divided by Average Daily Demand for the item.
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
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
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.
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 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.
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
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.
Line TAKT As Assigned
Red—Resource overcapacity or IPK overcapacity is greater than 0
Yellow—Line TAKT As Assigned is greater than Line TAKT
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
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
Resource, Needed, Relocation Needed
Red—Resource Needed is greater than Resource Assigned
Yellow—Relocation Needed = Yes
Line, Operation, Resource Needed, IPK Needed
Red—Resource Needed is greater than Resource Assigned
Red—IPK Needed is greater than IPK Assigned
Department, Unit, Total Unit
Red—Unit is less than Assigned
Red—Total Units is greater than Total Assigned
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
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.
Needed (blue) and Assigned (green) values are displayed next to each other for comparison.