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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 3.2 Number the Process Columns

Mixed Model Line Design Certification Project Exercise 3: Process Commonality Task 3.2 Number the Process Columns
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Add a row directly above the process names, and number them 1 through n, with n being the total number of processes – 9 in this case.

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