Tombro Industries is in the process of automating one of its plants and developi
ID: 2467312 • Letter: T
Question
Tombro Industries is in the process of automating one of its plants and developing a flexible manufacturing system. The company is finding it necessary to make many changes in operating procedures. Progress has been slow, particularly in trying to develop new performance measures for the factory.
In an effort to evaluate performance and determine where improvements can be made, management has gathered the following data relating to activities over the last four months:
Tombro Industries is in the process of automating one of its plants and developing a flexible manufacturing system. The company is finding it necessary to make many changes in operating procedures. Progress has been slow, particularly in trying to develop new performance measures for the factory.
In an effort to evaluate performance and determine where improvements can be made, management has gathered the following data relating to activities over the last four months:
Tombro Industries is in the process of automating one of its plants and developing a flexible manufacturing system. The company is finding it necessary to make many changes in operating procedures. Progress has been slow, particularly in trying to develop new performance measures for the factory In an effort to evaluate performance and determine where improvements can be made, management has gathered the following data relating to activities over the last four months Month 2 Quality control measures 139 45 94 178 Number of defects Number of warranty claims Number of customer complaints 200 61 97 42 73 54 Material control measures 8 days 7 days 5 days 4 days Purchase order lead time Scrap as a percent of total cost 7% 7% 2% 3% Machine performance measures Machine downtime as a percentage of availability Use as a percentage of availability Setup time (hours) 4% 94% 5% 91% 5% 88% 8% 84% Delivery performance measures Throughput time Manufacturing cycle efficiency (MCE) Delivery cycle time Percentage of on-time deliveries 95% 94% 91% 88% The president has read in industry journals that throughput time, MCE, and delivery cycle time are important measures of performance, but no one is sure how they are computed. You have been asked to assist the company, and you have gathered the following data relating to these measures Average per Month (in davs Wait time per order before start of production Inspection time per unit Process time per unit Queue time per unit Move time per unit 2 12.0 0.6 2.7 5.1 0.6 13.0 0.6 2.6 6.2 0.6 10.0 0.7 2.8 0.6 8.6 0.7 0.4Explanation / Answer
1.a) Throughput time is the amount of time it takes for a manufacturer to make a product. The throughput time of a product is calculated by adding the four steps of the manufacturing process: process time, inspection time, move time, and queue time.
E
Throughput Time - Days
(A=B=C=D)
1.b) Manufacturing Cycle Efficiency (MCE)
MCE = Value-added time / Throughput time
Value added time is the process time
1.c) Delivery Cycle Time
The amount of time from when an order is received from a customer to when the completed order is shipped is called delivery cycle time (ie., Wait Time + Throughput Time).
3.a) New Throughput time
Throughput time = inspection time + process time +Queue time + move time
=0.6 + 1.1 + 0 + 0.7
= 2.4 DAYS
MCE = 1.1/2.4 = 45.83%
3.B) New Throughput time
Throughput time = inspection time + process time +Queue time + move time
=0 + 1.1 + 0 + 0.7
= 1.8 DAYS
MCE = 1.1/1.8 = 61.11%
Sl No. Particulars M1 M2 M3 M4 A Inspection Time 0.7 0.6 0.6 0.6 B Process Time 2.8 2.7 2.6 1.1 C Queue Time 4.1 5.1 6.2 8.6 D Move Time 0.4 0.6 0.6 0.7E
Throughput Time - Days
(A=B=C=D)
8.0 9.0 10.0 11.0