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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 1.2: Create Process Matrix Spreadsheet(s)

Mixed Model Line Design Certification Project Exercise 1: Documenting Products and Volumes Task 1.2: Create Process Matrix Spreadsheet(s)

Open and build an Excel spreadsheet using the template below titled “Process Matrix”.  Column titles, left to right, will be:  “Part #”, “Description”, “Daily VOL”, plus nine additional columns. These will be for Processes in Exercise 2. Populate Daily VOL column with your data.  Save your file!

PROCESS MATRIX
Part #DESCRIPTIONDaily VOL     
DR12Drill      
DR54Drill      
DR11Drill      
SD04Belt Sander     
CS87Circular Saw      
OS31Orbital Sander      
OS01Orbital Sander      
CH96Chain Saw      
CH09Chain Saw      
THROUGHPUT BY PROCESS       

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