Tesina lean production "dimensionamento sistema di produzione"

CALCOLO DELL'OEE CONSIDERANDO LE PERDITE DI CAMBIO

FINAL ASSEMBLY: 22,008 h - (4 C/O * 1 h) = 18,008 h / 24 h = 75%

ACTUATOR PRODUCTION: 1215,36 min - (2 C/O * 60min) = 1095,36 min / 1440min = 76%

AMPLIFIER PRODUCTION: 1100,16 min - (0 C/O * 60min) = 1100,16 min / 1440 min = 76,4%

BODY PRODUCTION: 1272,96 min - (3 C/O * 60min) = 1092,96 min / 1440 min = 75,9%

STEP 6) DEFINITION OF EPEI:

CUSTOMER AVERAGE DAILY CUSTOMER DEMAND C/O EPEI NPK(pz/d) (avg/d)

VW (1120 + 1160)/10 = 228 1 1 40

RENAULT (960 + 1440)/10 = 240 1 1 40

DAIMLER (400 + 400)/10 = 80 0,5 2 40

BMW (400 + 400)/10 = 80 0,5 2 40

AUDI (160 + 240)/10 = 40 0,5 2 40

PEUGEOT (240 + 260)/10 = 40 0,5 2 40

TOT 708 4

STEP 7) AVERAGE N° OF CARDS/DAY

STEP 8a) LEVELING PRODUCTION PLAN

CUSTOMER DEMAND IN CARDS/DAY CUSTOMER DAY1 DAY2 DAY3 DAY4→

VW (228/40) = 5,7 6 VW 6 6 6 6

RENAULT (240/40) = 6 → FLOATING RUNNER RENAULT 6 6 6 6

DAIMLER (80/40) = 2 DAIMLER 4 0 4 0

BMW (80/40) = 2 BMW 0 4 0 4

AUDI (40/40) = 1 AUDI 2 0 2

1. PEUGEOT (40/40)= 1 PEUGEOT 0 2 0 2TOT 18 TOT 18 18 18 18
2. STEP 9) CALCULATION OF REQUIRED DECOUPLING:
• (A) DEFINE "RE":

Rt Loop = 3 days➔ RE = Rt Loop/(TT * NPK)= (Rt Loop * PR)/ (POT * NPK)= (3 * 240)/ (1 * 40)= 18 Kanban

• (B) DEFINE "LO":

LO= (Lot Size/NPK) - 1 = 0 (piano livellato)

• (C) DEFINE "WI":

WI= KANBAN TOT - RE - LO= 26 - 18 - 0 = 8 REPLENISHMENT TIME (RE) = 18

3. PROCESS K SPOT 1 = 6 TOT. KANBAN REQUIRED FOR THE LOT SIZE FORMATION (LO) = 0
4. SUPERMARKET K SPOT 2 = 6 PLANNED SET UP PLANNED CUSTOMER
5. OVER FLOW K SPOT = 14 WITHDRAWAL PEAKS (WI) = 8
6. CALCULATION OF SA1 PACEMAKERS

A1 (SUPERMARKET)

7. (1) CALCULATE THE BIGGEST LOSSES CUMULATED IN THE RT LOOP

100(%) 90PERFORMANCE 80 75%7060 71 717050OEE 40 DAY 8 DAY 9 DAY 10→ →DAY 8: 75% : 18K = 70% : x K x K= 16,8 LOSSES= 1,2 CARDS→ →DAY 9: 75% : 18K = 71% : z K z K= 17,04 LOSSES= 0,96 CARDS→ →DAY 10: 75% : 18K = 71% : w K w K= 17,04 LOSSES= 0,96

CARDS(2) CALCULATE THE NUMBER OF CARDS TO COVER THE BIGGEST LOSSES IN THE RT LOOP→SA1 (SUP) = 1,2 + 0,96 + 0,96 = 3,12 3 K

SA1 (OVERFLOW)(1) CALCULATE THE BIGGEST PERFOMANCE INCREASE CUMULATED IN THE RT LOOP→ →DAY 4: 75% : 18K = 80% : m K M K= 19,2 INCREASE= 1,2 CARDS→ →DAY 5: 75% : 18K = 79% : n K n K= 18,96 INCREASE= 0,96 CARDS→ →DAY 6: 75% : 18K = 78% : l K l K= 18,72 INCREASE= 0,72 CARDS(2) CALCULATE THE NUMBER OF CARDS FOT THE BIGGEST POSITIVE PERFOMANCE IN RT LOOP→SA1 (OVERFLOW) = 1,2 + 0,96 + 0,72 = 2,88 3 K

10090(%)PERFORMANCE 80 75%7060 80 79 78OEE 5040 DAY 4 DAY 5 DAY 6

SA2: N° OF CARDS TO COVER UNPLANNED CUSTOMER FLUCTUATION (EXTERNAL FLUCTUATION)BIGGEST DEMAND INCREASE SA2(SUP)?→DAY 3 0 CARDS→DAY 4 4 CARDS SA2(SUP) = 4 K→DAY 5 0 CARDSBIGGEST DEMAND DECREASE SA2(OVERFLOW)?→DAY 7 1 CARDS→DAY 8 1 CARDS SA2(OVERFLOW) = 3 K→DAY 9 1 CARDS

DESIGN OF PRE-PROCESSDEFINE “RE”RE = Customer daily demand

(avg K) * Rt Loop

Rt Loop= 2 gg

Customer daily demand GREEN BODY: RENAULT = 2gg * 6k

BMW = 1gg * 4k

➔ RE (GREEN BODY) = Rt Loop/(TT * NPK) = (Rt Loop * PR)/(POT * NPK) = [(2 * (6 + 6 + 4)/2)] / (1 * 1) = 16 k

Customer daily demand AMPLIFIER: VW = 2gg * 6k

RENAULT = 2gg * 6k

DAIMLER = 2gg * 6k

BMW = 1gg * 4k

AUDI = 1gg * 2k

PEUGEUT = 1gg * 2k

➔ RE (AMPLIFIER) = [2 * (18 *2)/2]/(1*1) = 36 k

DEFINE “LO”

➔ LO = 0

DEFINE “WI” GREEN BODY

10

BODY 86

GREEN 42

WA 0 DAY 1 DAY 2 DAY 3 DAY 4

RENAULT BMW →

WA = picco di prelievo cumulato in Rt Loop WA (GREEN BODY) = WA(DAY 1) + WA(DAY 2)= 6 + 10 = 16K

➔ WI (GREEN BODY) = WA – RE – LO = 16 – 16 – 0 = 0 K

AMPLIFIER

20181614

AMPLIFIER 12108

WA 6420 DAY 1 DAY 2 DAY 3 DAY 4

VW RENAULT DAIMLER AUDI

WA (AMPLIFIER) = WA(DAY1) + WA(DAY 2)= (6 + 6 + 4 + 2) + (6 + 6 + 4 + 2)= 18 + 18= 36 K

➔ WI (AMPLIFIER) = 36 – 36 – 0 = 0 K

SA1 (SUPERMARKET)

(1) CALCULATE THE BIGGEST LOSSES CUMULATED IN THE RT LOOP→

→DAY 7: 75,9% : 18k = 74% : x K x K = 17,55 K LOSSES = 0,45 K→

→DAY 8: 75,9% : 18k = 73% : z K z K = 17,31 K LOSSES = 0,69 K→

→(2) SA1(SUP) = 0,45 + 0,69= 1,14 1 BODYSA1 (EXTRA K)(1) CALCULATE THE BIGGEST PERFOMANCE INCREASE CUMULATED IN RT LOOP→

→DAY 1: 75,9% : 18k = 79% : m K m K = 18,74 K INCREASE = 0,74 K→

→DAY 2: 75,9% : 18k = 79% : n K n K = 18,74K INCREASE = 0,74 K→

→(2) SA1(EXTRA K) = 0,74 + 0,74 = 1,48 1 BODYSA2(SUP) = SA1 (LEV BOARD) PACEMAKER = 3 KSA2(EXTRA K) = SA1(SUP) PACEMAKER = 3 K