Assembly line process capacity assessment

S

S N

I have to depict my manufacturing assembly line in the form of a flow chart.
The flow chart should also tell me the time taken in each activity, and help
me assess the assembly line manufacturing capacity per year or per week.
Can anyone please help me by advising if it is possible in microsoft
project, and if not, any other software which can help me in doing that.
 
J

Jim Aksel

You may want to consider using two products.
First, MS Project will allow you to enter all the tasks, resources required
to do the job, etc. You can potentially determine capacities by monitoring
if resources are overloaded (resource views in Project).

MS Project will allow you to display this in flowchart form as a Network
Diagram which will also display several formats of the data including what
you want. So, I think MS Project can do most of what you need.

There is an add-on to MS Project called Pert Chart Expert
(www.criticaltools.com) which offers some additional flow charting features
and filtering.

Another product to consider would be Microsoft Visio. It also has
timeline/Gantt type capabilities and would be more robust than Project in
creating flow charts, etc. However, analysis of the data in Visio might be
more of a challenge. Visio will exchange data with MS Project so you can
get some benefits there too.

Microsoft has free evaluation copies of Project and Visio available on the
Microsoft Website.
--
If this post was helpful, please consider rating it.

Jim

Visit http://project.mvps.org/ for FAQs and more information
about Microsoft Project
 
S

S N

I have seen it. However, please note, I need to assess the capacity of the
assembly line for which I draw the flow chart. I dont think ms project does
the calculation of capacity of the process flow chart.
Please help.
 
S

S N

i want to find out the number of components that can be produced from an
assembly line. I have the time required for each process on each
workstation, and have drawn rough flow chart for the full process. The plant
works two shifts per day (16 hours).
Please advise if this can be achieved by MS Project. If not, please advise
on an alternate software for the purpose.
 
J

Jim Aksel

What project can do for you is identify your critical path through the
network.
Enter each production step as a task and give it a duration. So, you might
have three tasks -- (1) Paint Component in paint station(0.5hrs), (2) Move to
oven (0.2hours), (3) Bake (4hours).

So, project will tell you how long it will take you to make 1 item if all
goes well.

Personally, I'd attack this problem with Excel.

What Project Cannot do for you is determine que wait times, etc. between
work stations. For example, if you have two ovens that will bake 48
components each you may have a que --- if painting only takes 0.5hours per
unit it is possible you will have 48 units show up at the oven before the
oven can accept them.

In my example, if you paint 1 unit at a time at one station, you will
achieve 48 units only once per day. Project will not know if you are allowed
to bake a partial batch. So, the oven might sit idle. If you have 24 paint
stations, you will que a full batch for each oven every hour.

I am not aware of any software that does this type of analysis for you out
of the box. For certain, with a good dose of VBA programming, you could get
Excel to do it.

This almost touches on Monte Carlo simulations. You may want to look at
something like Crystal Ball (it works with Excel). Then you could make
several production runs and base your capapcity calculation on a statistical
bet of how long each process will take. That is... does painting really take
30 minutes every time, or, is it sometimes 24 minutes and other times 42
minutes.


--
If this post was helpful, please consider rating it.

Jim

Visit http://project.mvps.org/ for FAQs and more information
about Microsoft Project
 
A

allanw1915

I have 15+ years of factory simulation experience. I highly recommend
ProModel Corporation's Process Simulator. PS works with a Visio front-
end. Very powerful, easy to learn & very affordable (~$2500) compared
to the full ProModel package. ProModel products are infinitely more
affordable & easy to use than DELMIA products. ProModel delivers
outstanding technical support too.

[ note: I do not work for ProModel Corp]

Good luck!

Allan
 

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