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Mixed Model Line Design Certification Project

Exercise 1: Documenting Products and Volumes
2 Tasks
Task 1.1: Calculate Daily Volume By Product
Task 1.2: Create Process Matrix Spreadsheet(s)
Exercise 2: Processes and PFDs
6 Tasks
Task 2.1 Study the Four Process Flow Diagrams
Task 2.2: Create Mixed Model Process Flow Diagram
Task 2.3 Create A Process Matrix
Task 2.4: Calculate Process Throughput (Volume By Process)
Task 2.5: Transfer Process Throughputs to the Mixed Model Process Flow Diagram
Task 2.6: Transfer data to the Excel Mixed Model Line Design Workbook
Exercise 3: Process Commonality
6 Tasks
Task 3.1 Make A Copy of the Process Matrix
Task 3.2 Number the Process Columns
Task 3.3 Replace “X” With Process Number
Task 3.4 Calculate Family Value
Task 3.5 Sort By Family Value
Task 3.6 Review Results
Exercise 4: Volume Adjustments
1 Topic
Task 4.1: Adjustments for Known Rework
Exercise 6: Work Content Times
2 Tasks
Task 6.1: Review pTool’s Standard Times data and Enter into Resource Calculation Spreadsheet
Task 6.2: Calculate Weighted Average Standard Time for Each Process.
Exercise 7: Resource Calculations
2 Tasks
Task 7.1: Enter the formula above in all the process cells on row titled “Required Resources”
Task 7.2 Define Locations
Exercise 8: Integrating Batch Machines
7 Tasks
Task 8.1: Complete Volumes
Task 8.2: Complete Run Time Per Piece
Task 8.3: Calculate Total Run Time
Task 8.4: Calculate Changeover Time Available
Task 8.5: Set Daily Changeovers
Task 8.6: Finalize Batch Sizes
Task 8.7: Calculate Required Bins
Exercise 9: Conceptual Layout
1 Topic
Task 9.1: Conceptual Line Layout
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Task 5.2: Calculate Takt Time

Mixed Model Line Design Certification Project Private: Exercise 5: Calculating Effective Minutes and Takt Time Task 5.2: Calculate Takt Time
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Takt Time is the “beat’, or tempo, of each process for the given volume and mix of product.  Think “Metronome”.  As a very simple example, assume we have a short day of 400 effective work minutes, and we need to produce 100 units.  So, over the course of the day, we must finish one unit every 4 minutes.  The formula to calculate Takt Time is:

Takt   =   Effective Work Minutes / Throughput by Process

                                   4.00   =                 400                       /                100

Show your Takt Time results in minutes, with two decimal places.

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