1. Process engineering
TAKT vs CYCLE

2. Objectives Satisfy the customer schedules Maintain company reputation
Improve productivity
Apply lean initiatives
Reduce manufacturing costs
Improve house keeping
Meet OHS requirements
Reduce WIP
Better utilisation of machinery
Improved QA

3. Balancing the sequence
Balancing the manufacturing sequence allows production to flow smoothly and improves manufacturing performance.
Balancing the manufacturing sequence reduces:
the amount of work in progress (WIP)
storage of parts
time wasting
QA issues
OHS.

4. Sequencing
Based on the TAKT time calculations we need to produce 60 cars per hour.
To achieve a specified rate of production the sequencing for machine and man time needs to be balanced across all process steps.

5. Process flow
Units per hour 45 90 40
The flow of work from one machine operation to the next affects production quantities.
In this example:
OP10 is producing 15 units more per hour
OP20 is not producing at the same rate as OP10
Note there is no inspection requirement on a roughing operation.

6. Capacity The capacity of: OP10 is 60 units per hour45
The capacity of:
OP10 is 60 units per hour
OP20 is 45 units per hour
Total production is reduced to 45 units per hour.
Work in progress is increasing by 15 units per hour.
1 day = 120 units WIP
5 days = 600 units WIP
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7. Assessing the process
Units per hour 45
Balance is achieved by identifying and assessing the sequence of process steps, to meet the demand of the TAKT time.
Improvements to the sequence can include:
modifying process steps
moving process steps
redistributing process steps to other machines.

8. Assessing change to process
Changes and modifications need to be assessed to identify how the manufacturing process may be affected.
Cost, availability or time can effect the final solution.
For example:
A fixtures ability to take extra load
Operator time
PFMEA/QA risk through changes
Costs.

9. Process sequence
Units per hour 45 90
One solution for balancing this manufacturing sequence is to move some sequence steps from OP20 to OP30.

10. Modifying the sequence
Units per hour 60 60
One step is moved from OP20 to OP30 = 20 seconds.
Now each of the three operations are balanced to operate in 60 second cycles.

11. Process cycle times The capacity of:
Units per hour 60 60 40
The capacity of:
OP10 is 60 units per hour – cycle time 60 secs
OP20 is 60 units per hour – cycle time 60 secs
OP30 is 60 units per hour – cycle time 60 secs
OP40 is 40 units per hour – cycle time 90 secs

12. Introduce new OP
Units per hour 60 60 60 60
30 seconds of the sequence is moved from OP40 to the newly created OP50. A manual machine will incur time penalties ie. 50 seconds.
OP50 is placed beside OP10 operator due to available operator idle time.

13. Summary TAKT time calculations to meet customer needs.
Identify equipment that cannot achieve TAKT time.
Identify the equipment sequence and activity.
Relocate equipment to meet TAKT time.
Use PFMEA to assess risk.
Introduced new OP.
Outcome achieved by balancing line.
Manufacturing supports customer needs.

14. End