24

_. _ _ _ _ _ _ _ _ _ _ _ _ _ _- _ _ _ _ _ _c_o_m_:p:__u_ter_In_t_:egrs~at:,:ed .M 1
- . '" Uf11cf!I .

- 1.17 PRODUCTION CONCEPTS AND MATHEMATIC~

. (DEC 2012, ·J UNE 2012 DE ~lj
2011
· Most of the production concepts are quantitative ie., which can be cal~ulat !
measured. These concepts need quantitative approach to ·measure them. Some 0 illld ;d
concepts are. f:- theSe
1. Cycle time
2. Production time and production rate
3. Plant capacity
4 . Utilization and availability
5. ManufacturiQ.g.lead time
6. Work-in-progress
7. WIP of TIP Ratio.
N otations used:
Tc = Cycle time (min)
T0 ·= Processing/operational time (min)
I I. Th = Work part handling time ~min) -
I I ,
T tt. = Tool handling time (min)
'.I T. p = Production time (min/Pc) .
T = Batch production time (min/Pc) .

T . = Job shop production time (min/Pc)

PJ
T = Mass production time (min/Pc)
pbn
R = Production rate (min/Pc)
p
R = Batch production rate (Pc/min)
Rpb = Job shop production rate (Pc/min)
PJ / • )
R = Mass production rate (Pc mm
pm -
P = Plant capacity (Pc/day)
s = Number of shifts per day (shifts/day)
C I'

H = Number of hours per shift (Hrs/shift)

n = Number of work stations (no units)
.. = Number of operations on each unit (no units)
no
u = Utilization (%)
A = Avajlability (%) . ; ·
MLT= Manufacturing lead tim_e (mm or Hours)
T = Non operational time (mm) .
/o = Stepup time (min)
SU
 25
Computer Integrated Manufacturing Systems

(1) Cycle time:-

Cycle time refers to the time spent by a product on the machine.
It is denoted by T0 Units : min/part
The time spent by the product i.e., cycle time will be productive as well as non .
productive. Productive time ineludes machining or operational time (T) ·
Non productive time includes works handling time (T11) and tool handling time (T th) .
:. Cycle_time, Tc =To +Th +Tth
(2) Production Time (T P) a.nd Production rate (RP)
Production time refers 'to the total time spent by the part in the shop floor.
Production rate refers to the number of parts produced during a period of time.
Usually. production
.
rate. is expressed in hours
•
and is denoted by R. p
.
Production rate is inverse of production time.
R =-1
P Tp
Production ti_me depends on the type of production systems:
(a) For bat~h processinQ system
For 'Q' Parts
Tpb =QT +T C SU

For each component, ·

T QTc+T,u =T +TN ,
pb Q C Q
,•I

Production rate:
Rpb :;= _l_ = Q , for each part, parts/Ill in
Tpb QTc +Tsu
(b) For job s/wp production sysiem, (Q = 1)
Production time:
TPJ. = Tc + Tsu .(min/part)
·
Production rate:
1·
Rp =~--(parts/min)
J Tc+ T,u
 . I,

26 Computer Integrated Ma
. . 11Ufac1~,14
g
(c) For mass production system {Q is very large/
Production time:
For each part:T =T + Tru
, p C Q
Since 'Q' is vel)' high, the quantity 'T,u / Q' is smallconipared to Tc and hence neglected
.·. Tp =;: Tc (for each part)
for 'Q' parts, TP = Q Tc
. l l '
Production rate, R =- = - (for 'Q' parts)
· P T QT·
p . ('

.(3) Plant capacity or Production capacity (Pc>

Plant capacity refers to the number of products that a production facility can produce
under certain operating conditions.
The various operating condition include:
(a) Number of shifts p~r. day(s)
(b) Number of hours per shift (H) ·
(c)Number of workstations (n)
(d) Employment levels,i .
(e) Production rate (R)
' p

- (f) Number of operations on each unit (n)

Plant capacity is given by, Pc= n.s.h.RP
Units: Shifts->< hours x parts = parts
· day Shift hours day

NOTE : In operations on each unit is considered; then plant citpacity is given by,
n.sR.RP .
Pc=---·- ~
. no
(4) U.tilization and availability
These are the two important parameters that are used to measur~ the performance oftbe
manufacturing plant.
.Utilization represents how best the resources are used in.the plant. .
It is denoted by 'U' and_is expressed in terms of'%'
If utilization is low, it represents high investments an low returns .
If utilization is I 00% and stiff the demand has not met it represents that the capacity of
the plant must be increased.
Utilization is also defi~ed as the ratio of number of units to the plant capacity
Compuf!1r Integrated Manufacturing Systems 27

. Q
U=-xlOO
pc
Ava~lability (A) refer:5 t~ the reliability of the· equipment. It also refers how best an
equipment can be mamtamed and serviced. · · . -
Availability depends on two reliability parameters
(a) Mean time between failure (MTBF) ·
(b) Mean time to repair (MTTR)
Availability is also expressed in terms of percentage
A= MTBF - MTTR x l OO -
MTBF

(5) Manufacturing Lead time (MLT)

Ml,T is a total time required to process a given parnhroughout plant
It is the time elapsed between the customer order and the product delivery.
MLT does not include the time spent by the work part before
.
starting th_e actual
' process ..
MLT depends on different types of production system.
MLT depends on step up time (T,.) and on non operational time Cf110) .

For Batch production system: ,, :i •

MLT = n (QT + T + T )- for same cycle time, operational time, .
B o c su no .1
setup time for all workstations . ·
n ·. ,

MLT t(QTci +Tsu+ T ;)-fordifferenttimesfordifferentworkstations. ·

110
8
i=I

For Job shop production system,

MLTi = ri 0
(Tc+ Tsu+ Too)

MLT
J~
= t'°'(Tci +Tsui+ Tm,J
i=l

For mass production system

MLTm =n (T) <J C

"·
MLTm =I:QTc
i=I
 1)
28
- -------------:-----~trir;~, Computer Integrated .Manu1.
.
(6) Work- in - process (WIP)
WIP refers to the number of workparts which are located in the factory that are
processed and the workparts which are in between processmg . operations.
. to 0e
WIP refers to the cost of inventory that is in the state of being transformed from
. l to the finished product.
matena · row
WIP = AU.Pc {MLT)
S.H
(7) WIP & TIP Ratio
.. These ratios are used to measure werks in process
WIP Ratio refers to the total number of parts on process relative to the nulllber of
processing machines WIP ratio helps to detennine the utilization of availability of the
machine ·
,.
WIP= WIP. .
Number of processing machines
WIP
- ·1 n.u.Tc.Q I
QTc +Tsu

TIP ratio refers to time in process. It is the time that a work part spents in a plant relative
to actual processing time
. MLT
TIP Ratio= - -
no Tc

Jr
 Comtuter Integrated.Manufacturing Systems 29

Formulae:-
(1) Cycle time:-_Tc= T0 ·+ T0 + T111 i
' (2) ·Production time for 'Q' parts ·
(a) Batch production Tp =·o T(' TSU +
(b) Job shop production
.
system Tp = T·C + TSU
(c) Mass.production TP .=QTC ..
(3) Production rate for each part
(a) Batch production system, R = . Q
P QTc + T,u•

(b) _Job shop production system,

l
(c) Mass production system R=-
P Tc
· . n.s.H.R
(4) Plant-capacity; ·Pc = · _P
. no
(5) Utiliz.ation, U = _g_ x 100
1
• -

pc .
. b"I" A MTBF - MTTR .
(6) Ava1 1a 1 1ty, = - - - - - - x 100
MTBF
(7) Manufacturing.lead time .
(a) Batch production system, MLTe = no (QTC +Tsu+ Too)
(b) Job shop production system, MLTi =n 0 (T0 +Tsu+ T00 )
(c) Mass production system MLTni = n .Q.T 0 0 ·

A.U.P0 .(MLT)
(8) WIP~ · . -
S.H
WIP
(9) WIP Ratio= ----e-
n.u.T0.Q
· QTc + Tsu
. . MLT
(10) TIPRatio=--
. no.Tc
 ·1 ,,t,
Computer Integrated Manufact
I'\
~ I n g
I t,,
Computer Integrated Manufacturing Systems 31
\ I ~I", I 30
i/. 1.1 a·.NUMERICAL EXAMPLES 1.3. A Manufacturing plant produces gas cylinders in a--'batch·size of_60 units and
I I
' requires a sequence of 8 operations in the plant. The average· set up time is 3
·•1.1. A workshop has '6 ·machines which produces identical parts and operat ,
,hffi• pu w""- Th<0omb<, of•••~
I"' shift .., to b< 6. Amag, p,.. ". 10
hours and the average operation time per machine is 8 min. The average non
operation time is 6 hours. How many days . it will take to produce a batch,
rate of each machine is 30 units per hour; Determine the weekly prodUct~on
• f' • UCho assuming that the plant o_perates on a 7 hours shift per day.
capacity o the machme shop. • · II Sol. Given.
Sol. Given, number of Work centers. n = 6_ Quantity of units in a batch : Q = 60 units
Number of shifts, S = I0/week. Number of operations, : n0 = 8
Number of hours, H = 6/shift '
Setup time, • · : T,. = 3 hours
Production rate. Rp =30 U~its,/hr '. 6
Production capacity, pc = nSHRp Operation time per machine : T0 = 8 min= 0.133 hours (cycle time) .
60
= 6 X 10 X 6 X 30
: Tc =T+T +Tth
P, = 10,800 Units/Week o b
:::::Th and T,hare not given in the problem; they are neglected and hence,
' 1.2. A production department operates 80 hours per week Its production rate is T =T
' • 0
20units per hour. During a Certain week the machine produced 1000 parts and Non operational time, : Tno= 6 hours
was idle in the remaining time. Determine the production capacity and machine I Manufacturing lead time,
utilization? M.L.T = n0 (T,.+ QT/ T,..,)
, Sol. Given, = 8 (3 +60 >< 0.133 + 6)
NU11lber of Workcenters, n = 1 = 135.84 hours.
Number of shifts, Number of hours, 135 84
I "' At 7 hours shit per day, · = 19.4 days 20 days.
S.H = 80 hrs/week .1 7
I
Production rate, RP =20 units/hour "' The plant takes· 20 days to complete batch production.
Actual production, Q= I000 parts 1.4.',Four products are to be processed through a certain.,type ofwor~ center. The
correspQnding·data is given in the following table. · ~'
Production capacity, P = ?
P.roduct Weekly Demand (Units) Production Rate (units/ hour)
Utilization, u = ? 1 500 10 .,
Production capacity 2 · 800 20
P =nSHR 3 1000 30
' p
,; I x 80x 20 4 2000 40
P, = 1600 UnitsfWeek Determine the number of work centers required to satisfy the demand. The
Utilisation plant works 10 shifts/weeks and thei:e are 7 hours available for production on
A,ctual production _ 1000 each work center for each shift. Th·e product undergoes only one operation at
U= . . -xlOO
. Production capacity 1600 each work center.
J U=62.5% Sol.
! 1
ii
 computer Integrated Manufaci«r· .
•ng
33
11,11\/ 32 Computer Int,.grated Manufacturing Systems
• • -~J Demand · ( Units ) Total Number of Work centers, n = 18
T1merequiredto.proc~seachpart- . Rate -0 mts
Production . /hr =hour
1
Plant operation time, SxH = 60 Hours/week (shift/week x hours/shift)
(a) Manufacturing lead time (MLT)
500
For product I
,
= -10 = 50 hours MLT = n0 (T.. + QT,+ T.)
= 7(5 + 25 X 0.J + )0)
800
For product 2 = - = 40 hours = 122.5. hours.
' 20
1000 (b) Production Capacity, P,
For product 3, = - - = 33.34 hours p =nSHR,p
30
2000 ' n.
For product 4, = .- -· = 50 hours
40 For Batch production,
Total production hours required to process= 50 + 40 + 33.34 + 50 = 173.34 hours. T _ QT, +T., _ 25x(0.l)+S
p- --Q--~ 0.3 hours/unit
Given that each plant can operate only IO shifts/week at 7 hours/shift
IO x 7 = 70 hours/week. 1 1
:.RP=-=-=3.34umts/hour.
· .
No. of production hours TP 0.3
No. of Workcenters =
No. of hours that each Machine can operate 18x60x3J4 .
: .P, - -7- - 515.314=516umts/week
.
17334
= =2.47workcenters
70 Actual production
(c) Utilization, U . .
=. 3 Workcenters Procu!ion Capacity
1.5. The average parts produced in a certain batch manufacturing plant must be Actual production= Number of batches x Number of units in each batch
processed through an average of7 machines. There are 20 new batches of parts · , = 20 x 25 = 500 units/week
launched each week. Average operation time is 6 min, average setup time is 500
5 hours, average bat~h size is 25 parts and the average ~on operation time I U=-x100=96.899%
516
per batch is 10 hourslinachine. There are 18 machines in the plant. The plant
operates on an average of 60 production hours per week. Scrap rate is negligible, 1.6. A Certain part is routed through 6 Machines in a batch production plant. The
setup and operation time for each machine is give1,1.in the following table. The
Determine (a) Manufacturing lead time for an average part, (b) plant capacity 1
(c) pl1mt utilization,. · batch size is 100 units and the average non-operation ti~e per machine in 12
Sol. Given, hours.
n. = 7 Machines I 2 3 4 5 6
0
Number -o f batches of parts = 20 Setup time (hrs) 4 2 8 3 3 4
Operation cycle time(min) 5 3.5 10 1.9 4.1 2.5
.
Average Operation . T . 6
time, , = 6 mm= =.0. I hour; . Determine (i) MLT (ii) Production rate for operation 3 and 5.
60
Average set up times Tsu= 5 hours Sol. Given,
i Batch size, Q = 25 parts n =6
I
0
' i_:!I 1
Non operation time, T,, = I0hrs/machi"!~
j 1: 0
I 11 l
. :h '
 11nl.
Computer Integrated t,{anufacturing
Computer Integrated Manufacturing Systems 35
34
\ {1\'I\ . . 5+3.5+10+l.9+4.1+2.5 27 =4.Smin Sol. Given:
1 Averagecyclet1me, T, 6 . 6 Number of shifts per week, S = 10 shifts/week
1 1 4.5 . Number of hours per shift, H = IO hrs/shift
T =-=0.075hours Production rate, Rp = 12 units/hour.
C 60
Number of machines, n = 8 ·
Q =!OOunits
MTBF = 1200 hours
T =12hours
MTTR = 24 hours
4+2+8+3+3+4 24 U = 80% = 0.08.
Averagesetuptime,T - - - - - -=4hours
"' 6 6 (i) Production capacity,
(i) Manufacturing Lead Time (MLT) Pc = n.S.H.Rp.
= 8xlOxIOx12
MLT = n. (QT, + Tsu+ T,.) = 6(100 x O.o75 + 4 + 12)
= 9,600 units per week
=141 hours (ii) Avalibility
(ii) Production rate for operation 3. A MTBF-MTTR
For Batch production, MTBF
TP = (QT, + T.,)/Q
= 1200-24 =0.98
·( 10 ) 1200
lOOx-+8
' 60 0.2467 A=98%
Tp
100 Given, U = 80% = 0.8
RP =_!__=-1-=4.054 piece/hr.=5 piece/hr p = A.U. n.S.H. Rp
r. 0.2467 = 0.98x0.85 x8x lOxlOx 12
Production rate for operation 5, Pc = 7997 units/week.
1.8 The average part produced in a certain batch manufacturing plant must be
T +T ) JOO x~+3
T (Q ·, su 60 processed through an average of six machines. There are 20 new batches of
P Q 100 parts launched each week. Other pertinent data are as follows.
";' 0.09833 hour/piece Average operation time=.6mins
I I . Average set up time= S hrs
:.RP =-=--=10.169p1eces/hour
TP 0.09833 Average batch size= 25 parts
• : . RP = 11 pieces/hour. Average non-operation time/ba~ch = 10 hrs.
There are 18 machines in the plant. The plant operates on an average of 70
1.7 A machine shop operates 10 shifts per week and each shift of 10 hours. The production hrs/week.
machine shop consists of 8 machines and with a production rate of 12 units per
(i) .Determine the manufacturing lead time for an average part.
hour for each machine.
(ii) Det~rmine the plant capacity.
(i) ·Determine the weekly production capacity of the machine.
(iii) Determine the plant utilization. (10 M. VTU, Jan 2010. June/July 2011. July 2015)
(ii) If the mean time between failures of the machine is 1200 hours; mean time
to repair in 24 hours & the utilization of the machines in the machine shop
IT is 80%, determine the wee' •'·! :>roduction capacity.
~ .
 Comput•r Integrated Manufacturing
36 Computer Integrated Manufacturing Systems
37
Sol. Given: n, = 6 500
Number of batches of parts = 20 .-. u= 702 x100
Tc= 6 min= 0.1 hour. U =71.225%
Tsu= S hours
1.9 In a manufacturing plant a part is produced in a batch size of 60 units. The
Batch size, Q = 25 parts. batch must be routed through eight operations to complete it. Average set-up
Tno = IO hours/batch. time 5 hr/operation & average operation time is 10min ..Average non-operation
n= 18 time is 7hrs/operation. Determine
Plant operation time, S x H 70 hours/week. [shift/week x hours/week] (i) Manufacturing lead time iii number of days of the-plant runs Shrs shift/day.
(a) Manufacturing lead time, (ii) Production rate of the plant (08M, Dec 20/J)
MLT = n0(Tsu + QTc + Taj Sol. Q=60units, T,=10min=~=0.166hr n =8,T =7hrT =ShShift=8hr/day
= 6(5+2S xO.l+ 10) 60 o no SU
MLT = I OS hours. a) Manufacturing lead time (ML'])
MLT = n.(QT, +Tsu+ T .)
(b) Production time, 0
= 8(60 x 0.166 + S+ 7)
7:P =--Q--(
QT, +Tw t, .
or batch production) = 175.68 hrs
MLT in number of working days
2Sx0.1+5
25 MLT= 175.68hrs
8hrs/ shift
T, = 0.3 hours per unit.
= 21.96days
_"" Production rate,
=22days
I I
R,=~=-=3.34units/hour
T, 0.3 b) Prod.uction rate of the plant
l Q 60
"" Plant capacity R,=- - ~ - ----=4pc/hr
Tp QTc+Tsu 60x0.166+5
P = n.S.H.Rp = 18x70 x3,34
C Il o 6 R, =4pc/hrx8hr/day
R,-=32pciday
P, = 701.4 ""702 units/week.
I 1.10 There are 24 machines in the manufacturing plant and the parts produced in a
(l) Plant Utilization, batch must-be processed through an average of eight machines. 24 new batches
are launched each week. Average operation time is 6 min. Average batch size is
Actual Production
U . C . 30 parts, average setup time is 6 hrs and average non-operation time per batch
Production apaclly is 12hr/machine. The plant operates an average of 80 production hours per week
and assume A= 95%. Determine .
Actual Production= Number of batches x Number of units in each batch.
= 20 X 25 i) Manufacturing lead time for an average port
Actual Production= 500 units/week ii) Production rate
iii) Plant capacity iv) Plant utilization v) WIP vi) WIP ratio (VTU, Jan 2014)
 ,, Computer Integrated Manufacturing Computer Integrated Manufacturing Systems 39
I
I 38
" ,, \· WIP
{ ·) WIP Ratio = (
Sol. Given VI n .U.Tc'Q ]
Q = )0 parts Number of Machines, n = 24
· QT,+T'"
T = 6min = 0.1hr Number of batches= 24
1435.19
x3{)]
C
I\=8 A=95%=0.95 -[--24 X 0.897 X 0.1
T. = 12hr 30x 0.1 +6
0
T.i =6hr 1435.19
. •
Shaft= 80hrs/week = S x H = Plant operation time 7.176
(i) MLT=n,(T, 0 +QT,+T, 0 ) • •
= 199.99"' 200 parts
=8(6+30x0.1+12) 1.11 A production machine is operated 65hr/week at full capacity with a production
= 168 hrs rate of 20 units/hour. During a certain week the machine produced 1000 good
(ii) Production rate (R,) parts and was idle in the remaining time.
(i) Determine the production capacity of machine
\I R=-
I I
' T, Production time (ii) What was the utilization of the machine during the week under consideration.
T = QT, + Tw 30 x 0.1 + 6 = 0.3 hours/ unit (YTU, July 2013)
' Q 30 Sol. Given,
:. R = _!_ = ...!... = 3.34 units/ hrs S x H = 65 hrs/week
' T, 0.3 Production rate, = 20 units/hour
nsH R 24 x 80 x 3.34 . Q = I000 parts
(iii) Plant capacity, P, = ' 801.6 umts / week
n, 8 n=l
:. P, = 802 units/ week (i) Prodution capacity
.(iv) Plant utilization
P=n.S.H.R,
U Actual production
= l x 65 x 20
Production capacity
=1300 units/week
Actual Production =No.of batches x No. of units in each batch
") U . . . U Actual production
= 24 X 30 ( 11 h 11zat1on, = - - ~ - - -
Production capacity
= 720 units/ week
Actual production= Q = 1000
:. U= ?20 xl00=89.77%
802 U=IOOOxlOO
(v) WIP 1300
=76.92%
WIP = A.U.P,.(ML T)
· S.H
0.95 X 0.897 X 802 X 168
!:I r
'Iii,,
80
= 1435.19"' 1436 parts
1
. , I.' I. ,,II There are 1436 units that are located in the factory that .are to be processe d an d .m
I\ I between processing operations.
l 'X
 Computer Integrated
___Manufactu ring
40 Computer Integrated Manufacturing Systems 41
\I
1.19 PROBLEMS FOR PRACTICE 6. An average of IO new orders is started through a certain factory each month. An order
1. IO Operations are required in a sequence to produce a piston of an automobile engin consists of an average 75 parts.to be processed through 8 machines in the factory. The
The piston is to be produced in a batch of I00 Units and . .the 14
average
M' setup time IS~- operation time per machine foe each part is 25 min. The non operation time averages
2 hours and the average operation time on each mac hme 1s mutes. The N to be plant operates 175 hrs/month. Determine ·
operational time is 5 hours. If the plant operates on a 8 hour shift per day determi~n · i. Manufacturing lead time.
Manufacturing lead time. e ii. Plant capacity
iii. Utilization
Sol. 38 days iv. Work in process
2. A new machine installed in a factory has a production rate of 25 units per·hour wh
v. TIP ratio.
working at 60 hours per week. Due to lower demand the machine was kept idle ;n 0
some tim_e and only 1200 units are produced. Determine the production capacity 0~ Sol. MLT =370hrs, PC= 8?3, U = 84%
the machme tool and its utilization during the low demand week. 7. In a certain-factory an average of 20 new orders is processed every month, 50 parts
are to be processed on an average for every order. The processing of the order is to
Sol. Pc= 1500 units/week, U = 80% be carrie~ out through IO machines in the factory. The operation time for machining
3. For three types of products the weekly demand and production rates are as follows:
each part is I5 mins, non - operation time per order at each machines is 8 hours
Production rate(Units / hour)
Product Weekly demand (Number ofunits) setup time per order is 4 hours, number of machines operational at anytime is 80%,
12 percentage of machines under repair and maintenance at anytime is 20%. Determine:
I 600
16 i. MCT, ii. Production capacity iii. Plant utilization iv. WIP ratio.
2 800 -
1200 22 (VTU Dec 2015)
3
The Number of shifts per week is 8 and the productive hours per shift is 8 hours for
each work center. Determine the Number of work centers required to meet the above
demand.
Sol. (n = 3)
4. A certain part is produced in a batch size of 50 units and requires a sequence of
8 operations in the plant. The average setup time in each machine is 3 hours and
the average operation time per machine is 6min. The average non operation time
due to handling, delays and inspection is 7 hours for each operation. Compute the
manufacturing lead time for each batch, assuming that the plant operates on a 8 hour
shift per day.
Sol. 15 days
5. A Workshop operates IO shifts/week and each shift is of 8 hours. It contains 6
automatic lathes which has an average production rate of IO units per hour. Determine
the weekly production capacity of the work cell. If the availability of lathes is 95%
and the utilization is 85%, what is the weekly production capacity of the work cell.
Sol. Pc = 4800 units/week, 3876 units/week