iSixSigma

Capacity Study

Six Sigma – iSixSigma Forums Old Forums General Capacity Study

Viewing 11 posts - 1 through 11 (of 11 total)
  • Author
    Posts
  • #46580

    Jatt
    Participant

    I am very new to the manufacturing business and I was directed to put together a capacity study to see whether we need new equipment with the projected volume.
    What is the method of doing the capacity study? Is there any general rule of thumb?
    Can someone please guide me as how to do a capacity study.
    (when I asked my  manager for help the answer was, ” I’m sure you will figure out on your own.”)
    Any help / guidance will be appreciated.
    Jatt

    0
    #154196

    narayanan
    Member

    Hi,
    I am sure I can help you, but to proceed, I need to know in specific which area/field you would like to do the capacity study, though you have metnioned manaufacturing indsutry, it is still vague. Becuase manaufacturing industry involves various activities that is right from procurement to manufacturing to daily despatch/sales.
    thanks
    sathya
     

    0
    #154205

    Jatt
    Participant

    Thanks Sathya!
    We are manufacturers of auto parts. Currently we weld some of the components manually and the others with a machine (robot). I would like to do a capacity study to see if we would be able to put the volume of the manually welded components on to the robot to reduce a head (manual welder).
    I hope this helps!
    Thanks again.

    0
    #154224

    jberillajr
    Participant

    Jatt,
    I assume you are looking for a way to measure maximum capacity.  Using a simple, straight forward lean approach, max. cap. is the maximum number of parts a process, line, or work cell can product in a given unit of time.  Usually, this is reported as a ratio of parts/shift or parts/hour.
    I like to identify each product family first (all products that use similar resources in similar amounts).  Then I like to map the value stream of each product family within the four walls of the facility (the physical route the product takes from raw material inventory to finished goods).
    Now for each process element or workcell, you can determine the amount of time that is available for work and from that subtract all planned down time (breaks, lunch, scheduled maintance, etc).  Now convert into sec (eg: 8 hr shift x 60 seconds x 60 minutes = 2880 sec) .  Now you have to determine your cycle time (CT).
    Go to your selected process element or work cell and follow a unit of production from start to finish. It is best if you can do so in such a manner as to keep the operate from knowing you are observing him/her (blind).  I like to have two people people measure 5-10 different units that move through the process element (more is better).  Now average the two measures, and then average the three….just helps to minimize the variation in the averages.  Now:
    Available Work Time / Cycle Time = Max Cap.
    Now the goal is to increase AWT and decrease CT through reduction of waste in the process, hence increasing MaxCap.  You will want to look at this reletive to Takt Time….good luck.

    0
    #154604

    Talaid
    Participant

    Jatt,
    I’ve done many of these studies and gone around too many mountains. The formula us accurate but deterimining the cycle time is where poeple can make it too complicated. Get your vendors involved, they can do a very accurate cycle time analysis using their equipment. What you need to determine is the customer driven TAKT time then let your vendor show you a process to beat it.

    0
    #154647

    Shelby
    Member

    Hi,
    Prior to doing a capacity study, I would advise you Lean Out your process.  Gain a true understanding of your current process.  Many times, companies assume that additional resources are needed to meet customer demand, when in fact the current resources are not being fully utilized. 
    Jumping to the conclusion that new equipment/facilites/personel is required to meet new or existing demand can lead to overspending.
    You may not have significant time, but you can do some simple tasks in a short period.  For example, hold a kaizen event in the area of interest.  You will be able to:
    1) learn the process very quickly
    2) remove waste
    3) identify other opportunities
    This method will get you closer to your stated goal and will improve your understanding of the process.
     
    Hope this helps,

    0
    #154794

    NASSIF TADROS
    Participant

    Shelby has came to a very good rating method, which is calculating the working hours, this is considered the YIELD, where the difference between that time in seconds and the full working hours (targeted) should be the Sigma rating.
    How to improve that sigma rating?
    The difference between the full (targeted) working hours and the actual working hours is simply = Failure time of the machines (Down time)+ Service time (maintenance) + environmental causes (as per history).
    The major variable to control here is the “Down time”, where you can use maintenance softwares to control the MTBF = Mean Time Between Failures.
    In case this is not enough then You Need A New Machinary.
    This is roughly according to the very little info about your production unit.
    B.Rgds

    0
    #154796

    Allthingsidiot O
    Participant

    Instead  of asking  every……….question,why  not  to  purchase some  SS-Lean  books and  save  sometime  to  educate  yourself?? 

    0
    #154797

    SS
    Member

    Allthingswhatever, why not to purchase some English Grammar book and save sometime to learn basic grammar… do you speaken English???

    0
    #154804

    Allthingsidiot O
    Participant

    I  enjoy  my  stupidity?would  you mind?

    0
    #154807

    SS
    Member

    let’s translate that for the not so stupid people: in the context of your all so revealing statement, do you mean: “do you mind”?

    0
Viewing 11 posts - 1 through 11 (of 11 total)

The forum ‘General’ is closed to new topics and replies.