tps cell: analysis and redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfraw 3...
TRANSCRIPT
![Page 1: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/1.jpg)
1
TPSCell:AnalysisandRedesign
1. Workflow(partseparatefromworker)
2. Standardwork(highlyspecified)
3. Productionrateflexibility
Ref:JT.BlackCh 4
![Page 2: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/2.jpg)
2
MachiningCell
Operator moves part from machine to machine(including “decouplers”)by making traversearound the cell.
![Page 3: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/3.jpg)
3
CellFeatures
• “Synchronized”,sequentialproduction• Operatordecoupledfromindividualmachines• Operatorintegratedintoalltasks• Goal:singlepieceFlow• Bestwithsinglecycleautomatics,butcanbedonemanuallytoo
SeeBrigg&StrattonVideo
![Page 4: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/4.jpg)
4
MachiningCellsegment Manual
(Sec)Walk to(Sec)
Machine(Sec)
1 Raw 3
2 Saw 15 3 60
3 L1 10 3 70
4 L2 12 3 50
5 HM 12 3 120
6 VM1 20 3 70
7 VM2 20 3 60
8 G 15 3 60
9 F.I. 19 3
10 Finishpart
3
Totals M+W = 153 490
12
3
4
5 6 78
9
10
Walking segments - 10
![Page 5: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/5.jpg)
5
MachiningCellManual(Sec)
Walk to(Sec)
Machine(Sec)
Raw 3
Saw 15 3 60
L1 10 3 70
L2 12 3 50
HM 12 3 120
VM1 20 3 70
VM2 20 3 60
G 15 3 60
F.I. 19 3 + 3
Totals M+W = 153 490
12
3456
7 8 910
1112
1314
Parts in the cell ~ 14
13parts
![Page 6: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/6.jpg)
6
StandardWorkforCell
Cell produces one part every 153 secNote: machine time Max (MTj) < cycle time CT
i.e. 120+12 < 153
![Page 7: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/7.jpg)
7
TPSCell
1. Productionrate=l
2. WIP=L?
3. Timeinthesystem=W?
![Page 8: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/8.jpg)
8
MachiningCell
12
3456
7 8 910
1112
13
Number of round trips; 13
Saw 3+15 + 153
#1 decoupler
1.5 +153
L1 1.5+ 10
+153
……. …….
Grind 1.5+15
+153
Manual and walk
19+3 out
150 153X13=1989
1989 + 150 = 2139
![Page 9: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/9.jpg)
9
ByLittle’sLaw
L=(13+1)X(150/153)+13X(3/153)=13.98parts
rate,l =1/153parts/second
W=153X13.98=2139sec
![Page 10: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/10.jpg)
10
TPSCell
Increaseproductionrate:
a)addadditionalworkertocell
b)modifymachinebottlenecks
![Page 11: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/11.jpg)
11
Manual(Sec)
Walk to(Sec)
Machine(Sec)
Raw 3
Saw 15 3 60
L1 10 3+3 70
L2 12 3 50
HM 12 3 120
VM1 20 3 70
VM2 20 3+3 60
G 15 3 60
F.I. 19 3 + 3
Totals M+W = 159 490
Work 1 80
Work 2 79
WORKER 1
WORKER 2
To increase production rate add 2nd worker
![Page 12: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/12.jpg)
12
Whatistheproductionrateforthisnewarrangement?Checkmax(MTj)<CT
Worker1; 80=80
Worker2; 12+120>79
Onepartevery132seconds
WearelimitedbytheHM(horizontalmill)
CanweshiftworkoffoftheHMtoreducethecycletime?
![Page 13: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/13.jpg)
13
Manual(Sec)
Walk to(Sec)
Machine(Sec)
Raw 3
Saw 15 3 60
L1 10 3+3 70
L2 12 3 50
HM 12 3 12080
VM1 20 3 7080
VM2 20 3+3 6090
G 15 3 60
F.I. 19 3 + 3
Totals M+W = 159 490
Work 1 80
Work 2 79
WORKER 1
WORKER 2
![Page 14: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/14.jpg)
14
StandardWorkforWorker#2
Cycle # 1 Cycle # 2
Operator waitingOn machine
+3
![Page 15: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/15.jpg)
15
WhatisthenewproductionRate?
Checkmax(MTj)<CT
Worker1; 80=80
Worker2; 110>79
HenceWorker#2willbewaitingon VerticalMill#2
![Page 16: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/16.jpg)
16
WhatisthenewproductionRate?
• Thenewproductionrateis;onepartevery110sec
• ProandCons;Worker“idle”,can’tspeedupbyaddingadditionalworker
• Designforflexibilitymake;Max(MTj)<CT/2
![Page 17: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/17.jpg)
17
Manual(Sec)
Walk to(Sec)
Machine(Sec)
Raw 3
Saw 15 3 60
L1 10 3+3 70
L2 12 3 50
HM 12 3 120
VM1 20 3 70
VM2 20 3+3 60
G 15 3 60
F.I. 19 3 + 3
Totals M+W = 159 490
Work 1 80
Work 2 79
WORKER 1
WORKER 2
A B
Alternative solution add 2 HM’s
Almostdouble!
![Page 18: TPS Cell: Analysis and Redesignweb.mit.edu/2.810/www/files/lectures/tps_cell_redesign_2017.pdfRaw 3 Saw 15 3 60 L1 10 3+3 70 L2 12 3 50 HM 12 3 120 VM1 20 3 70 VM2 20 3+3 60 G 15 3](https://reader033.vdocument.in/reader033/viewer/2022060507/5f1fce0344607025af2e69f5/html5/thumbnails/18.jpg)
18
TPScellsummary
1. Originalcell- 23.5parts/hr2. Additionalworker- 27.3parts/hr3. Shiftwork- 32.7parts/hr4. AddadditionalHM 40parts/hr