Operation Management

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HW5_Starter_Rosemount.xls
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Rosemount

Input Data Natural From Breakdowns From Set Ups From Re-work** Summary
Operation Machines Raw Processing Time (hrs) Natural Std Dev (hr) Hrs/day Yield Jobs Between Rework Set Up Time (hrs) Set up SD (hrs) Units b/n Setups MTTF (hrs) MTTR (hrs) MTTR- VAR Avail Batch In Batch Out Eff Process Time Eff Var Eff SCV Eff Process time Eff Var Eff SCV Eff Process time Eff Var Eff SCV Eff Process Time Eff Var Eff SCV Eff Process Time Eff SCv Effective Rate of 1 Machine Effective Workstation Rate (jobs/hr)
Welding 5 0.262 0.15 8 99% 100.0 0.03 0.01 1 40 0.17 0.1 99.6% 1 1 0.26 0.02 0.33 0.26 0.0235 0.34 0.29 0.02364 0.28 0.30 0.02 0.28 0.30 0.28 3.38 16.89
Hydro 1 0.019 0.03 8 96% 25.0 0.15 0.01 5 40 0.17 0.17 99.6% 1 1 0.02 0.00 2.49 0.02 0.0010 2.75 0.05 0.00462 1.92 0.05 0.00 1.88 0.05 1.88 19.59 19.59
Sensoring 1 0.025 0.006 8 95% 20.0 0 0 5 40 0.17 0.17 99.6% 1 15 0.03 0.00 0.06 0.03 0.0002 0.25 0.03 0.00016 0.25 0.03 0.00 0.29 0.03 0.29 37.93 37.93
A 1 0.31 0.29 16 100% 9,999,999 0.07 0.04 1 20 0.5 0.5 98% 15 15 0.31 0.08 0.85 0.32 0.0973 0.96 0.39 0.09867 0.65 0.39 0.10 0.65 0.39 0.65 2.56 2.56
B 1 0.31 0.23 16 100% 9,999,999 0.08 0.04 1 20 0.5 0.5 98% 15 15 0.31 0.05 0.53 0.32 0.0668 0.65 0.40 0.06850 0.42 0.40 0.07 0.42 0.40 0.42 2.48 2.48
C 1 0.24 0.37 18 100% 9,999,999 0.06 0.03 1 20 0.5 0.5 98% 15 15 0.24 0.14 2.32 0.25 0.1542 2.47 0.31 0.15517 1.58 0.31 0.16 1.58 0.31 1.58 3.19 3.19
D 1 0.15 0.31 16 100% 9,999,999 0.05 0.03 1 20 0.5 0.5 98% 15 15 0.15 0.10 4.41 0.15 0.1084 4.65 0.20 0.10909 2.60 0.20 0.11 2.60 0.20 2.60 4.88 4.88
E 1 0.18 0.17 16 100% 9,999,999 0.07 0.03 1 20 0.5 0.5 98% 15 15 0.18 0.03 0.92 0.18 0.0365 1.12 0.25 0.03755 0.62 0.25 0.04 0.62 0.25 0.62 4.06 4.06
Config 1 0.03 0.006 8 85% 6.7 0 0 1 40 0.17 0.17 99.6% 15 1 0.03 0.00 0.04 0.03 0.0002 0.20 0.03 0.00019 0.20 0.03 0.00 0.31 0.03 0.31 28.86 28.86
Test 1 0.023 0.006 8 99% 100.0 0 0 1 40 0.17 0.17 99.6% 1 1 0.02 0.00 0.07 0.02 0.0002 0.28 0.02 0.00015 0.28 0.02 0.00 0.29 0.02 0.29 42.87 42.87
Inspection 1 0.015 0.006 8 99% 100.0 0 0 1 9999999 0.0001 0 100.0% 1 1 0.02 0.00 0.16 0.02 0.0000 0.16 0.02 0.00004 0.16 0.02 0.00 0.17 0.02 0.17 66.01 66.01
Packing 1 0.015 0.006 8 100% 1,000,000.0 0 0 1 9999999 0.0001 0 100.0% 1 1 0.02 0.00 0.16 0.02 0.0000 0.16 0.02 0.00004 0.16 0.02 0.00 0.16 0.02 0.16 66.67 66.67
Figure 7: The Vortex Flow Lab Production Data
Line Scale Product Avg. Weekly Demand (units) Std Dev of Demand (units) Var. of Demand (units2) Long Run Avg. Mix Process Time (min.) Setup Time (min.) Run Time per Week (min.) Total Time per Scale (min.) Process Time (hrs) Set up (hrs)
1 A M 6.668 1 1 0.01 48 9 380.08 2070.41 0.8 0.15
1 A V 70.014 5 25 0.09 17 4 1470.29 0.28 0.07
2 A M 6.668 5 25 0.01 12 4 106.69 0.20 0.07
3 A M 6.668 5 25 0.01 13 4 113.36 0.22 0.07
3 B M 6.668 1 1 0.01 35 8 286.72 2690.54 0.58 0.13
4 B M 16.67 1 1 0.02 43 7 833.50 0.72 0.12
4 B M 10.002 1 1 0.01 22 7 290.06 0.37 0.12
4 B V 80.016 7 49 0.10 12 4 1280.26 0.20 0.07
5 C M 16.67 1 1 0.02 54 6 1000.20 4981.00 0.90 0.10
5 C M 16.67 1 1 0.02 41 6 783.49 0.68 0.10
5 C V 116.69 7 49 0.15 10 3 1516.97 0.17 0.05
5 C V 120.024 8 64 0.15 10 4 1680.34 0.17 0.07
6 D M 10.002 1 1 0.01 40 6 460.09 2817.23 0.67 0.10
6 D V 123.358 8 64 0.16 8 3 1356.94 0.13 0.05
6 D V 100.02 7 49 0.13 7 3 1000.20 0.12 0.05
7 E M 10.002 1 1 0.01 23 6 290.06 1210.24 0.38 0.10
7 E M 16.67 1 1 0.02 22 6 466.76 0.37 0.10
7 E V 56.678 3 9 0.07 5 3 453.42 0.08 0.05
Totals 790.16 19.18 1.00 13769.42 13769.42

Functions

Name Description Parameters
BreakVar Formula for breakdown variability BreakVar(NatVar, A, MTTR, MTTR-VAR,T-O)
NonPreVare Formula for set-up or recycle NonPreVar(NatVar, StdDevSU, N, SUTime)