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Production Performance Metrics Formulas

Cycle time analysis defines cycle time (Tc) as the time interval between when one work unit begins processing and the next unit begins. Tc is equal to the sum of the operation time (To), handling time (Th), and tool handling time (Tt) if applicable. The production rate for job shop production (Rp) is calculated by taking the reciprocal of the average production time (Tp), which is equal to the sum of the setup time (Tsu) and cycle time (Tc). For batch production, the batch processing time (Tb) is equal to the setup time (Tsu) plus either the product of the cycle time (Tc) and batch quantity (Q) for sequential batch processing

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64 views2 pages

Production Performance Metrics Formulas

Cycle time analysis defines cycle time (Tc) as the time interval between when one work unit begins processing and the next unit begins. Tc is equal to the sum of the operation time (To), handling time (Th), and tool handling time (Tt) if applicable. The production rate for job shop production (Rp) is calculated by taking the reciprocal of the average production time (Tp), which is equal to the sum of the setup time (Tsu) and cycle time (Tc). For batch production, the batch processing time (Tb) is equal to the setup time (Tsu) plus either the product of the cycle time (Tc) and batch quantity (Q) for sequential batch processing

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irtikadar2003
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd

Production Performance Metrics Formulas

Cycle Time Analysis


For a unit operation, the cycle time Tc is the time that one work unit spends being
processed or assembled. It is the time interval between when one work unit begins
processing (or assembly) and when the next unit begins. Tc is defined as:
Tc = To + Th + Tt
where Tc = cycle time, min/pc; To = time of the actual processing or assembly operation,
min/pc; Th = handling time, min/pc; and Tt = average tool handling time, min/pc, if such an
activity is applicable.

Production Rate for Job Shop Production


Tp = Tsu + Tc
Rp = 60 / Tp
where Tp = average production time, min/pc; Tsu = setup time to prepare the machine to
produce the part, min/pc; and Tc = cycle time from Equation (3.1). The production rate for
the unit operation is simply the reciprocal of production time, usually expressed as an
hourly rate: Rp = hourly production rate, pc/hr.

Production Rate for Batch Production


In sequential batch processing, the time to process one batch consisting of Q work units is
the sum of the setup time and processing time, where the processing time is the batch
quantity multiplied by the cycle time, that is,
Tb = Tsu + QTc
where Tb = batch processing time, min/batch; Tsu = setup time to prepare the machine for
the batch, min/batch; Q = batch quantity, pc/batch; and Tc = cycle time per work unit,
min/pc.
In simultaneous batch processing, the time to process a batch consisting of Q work units is
the sum of the setup time and processing time, where the processing time is the time to
simultaneously process all of the parts in the batch, that is,
Tb = Tsu + Tc
Tp = Tb / Q
and production rate is calculated using Equation (3.3).

Production Rate for Quantity-Type Mass Production


For quantity-type mass production, the production rate equals the cycle rate of the machine
(reciprocal of operation cycle time) after production is underway and the effects of setup
time become insignificant. That is, as Q becomes very large, (Tsu/Q) -> 0 and
Rp ~ Rc = 60 / Tc
where Rc = operation cycle rate of the machine, pc/hr, and Tc = operation cycle time,
min/pc.
Production Rate for Flow-Line Mass Production
For flow-line mass production, the production rate approximates the cycle rate of the
production line, again neglecting setup time. However, the operation of production lines is
complicated by the interdependence of the workstations on the line. The production rate
can be determined by taking the reciprocal of Tc as
Rp = 60 / Tc
where Rp = theoretical or ideal production rate, pc/hr, and Tc = cycle time from Equation
(3.7).

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