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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 6.1: Review pTool’s Standard Times data and Enter into Resource Calculation Spreadsheet

Mixed Model Line Design Certification Project Exercise 6: Work Content Times Task 6.1: Review pTool’s Standard Times data and Enter into Resource Calculation Spreadsheet

Task 1:  Review pTool’s Standard Times data and enter into Resource Calculation spreadsheet.  This data is on page 2 of this exercise; all information is in minutes.  The times represent the total time for each product in that process, and usually involve many individual work steps.  As you can see, the Standard Times within a process can vary widely according to the product or model.

You will also see that five processes – Mold, Grind, E-Test, Final Test, and Pack – involve both labor and machine work.  Since a successful Line Design will require both enough labor available and adequate machine capacity, we must incorporate Standard Times for both labor and machines.  So, open your Resource Calculation spreadsheet, and do the following:

  • For each of the five process columns listed above, insert a column to the RIGHT.
  • Above the row of the first product (DR12 Drill), insert a row.
  • In the added row, type “Labor” and “Mach” sub-headings for the five two-column processes.
  • In the top row, do “Merge/Center” for the column heads.
  • Transfer Standard Times data into your spreadsheet, and review for accuracy.
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