Calculation of Potential piece per hour

Subject:   Calculation of Potential piece per hour.

1.    What is cycle time?

 Cycle check: cycle check is a work measurement technique to measure the time taken the operators, when they are performing their jobs by using a stopwatch.

v  This is the time of one work start to next work touch duration with rhythm. Generally, ten time taking for find the potential or capacity pieces.

     

2. How can take the time?

v  When worker done the work in this moment observer taking the time by stopwatch from her or his behind or front of workstation.

3. What is average time and how can calculate?

v  This is the average of cycle time. Total cycle time divide by no. of cycle.

Calculation:

Note: When we calculate average time, we deduct from list any abnormal cycle time. 

Cycle time second = 35, 37, 34, 42, 58, 37, 38, 55, 35, 36.

                                                 35 + 37 + 34 + 42 + 37 + 38 + 35 + 36

Average time (second) = ---------------------------------------------------- 

(Observe time)                                           8

                                          = 36.75.

                                                  36.75

Average time (Minutes) = ----------

                                                 60

                                            = 0.61

  4. Bundle time.

v  It is the time of bundle open & tide. We are allocating for bundle time is 0.02 mts. Average one piece.

So,

Average cycle time (minutes) = 0.61 + 0.02 (BUNDLE TIME)

                                                          = 0.63

5. Allowance time.

v  A worker can not and does not work continuously throughout her full working hours. As such, take out bobbin case, replace a blunt needle, talk to the supervisor or quality inspector, a small rest to recover from fatigue, go to bathroom, etc. Workers are entitled this way to some type of extra time. This type of time allowed to operators for some unavoidable but non-performing task is called allowance.

    Allowances are two types. Relaxation & contingency allowance

Note:

  We know standard allowance is (17% - 20%).

  However, we allocate in this moment is 30%.

So,

  Average time + Allowance %

= 0.63 + (0.63 X 30%)

= 0.63 + 0.19

= 0.82

6. What is a potential piece?

v  How many pieces operator can be done. This is call potential or capacity piece.

  So,

   We know one hour = 60 minutes.

   Average time = 0.82

                                60

Potential pieces = -------

                                 0.82  

                               = 73 pcs.

Subject:   Calculation of Efficiency.

1. What is SMV (Standard Minutes Value)?

v  Standard time of operators is the time, which a qualified operator should take to complete it if the she works at standard performance (at the ratting of 100%) and provided she takes extra time allowed to her as allowance.

This called standard time or Standard Minutes Value.

2. Available minute calculation.

v  How many operators used in a line or factory a day for production, evaluate by minutes this call available minutes.

Say,

  One line has 20 opt. working times 8 hrs.

So,

   Available minutes = No. of workers X Working minutes

   = 20 x 8 x 60

                                       = 9600.

3. Earn minutes calculation.

v  How much production or output pieces come by using operators a day evaluates by minutes this call earn minutes.

Say,

One line output is 550pcs. SMV: – 6.20.

So,

Earn minutes = Production/ Output pieces X SMV

                          = 550 X 6.20

                        = 3410.

4. Efficiency.

v  How effective have we been?

Formula of Efficiency,

          

                                Earned minute

        Efficiency = ------------------------------------------ X 100

                              Available minutes

                                   

           Say,

            No. of worker – 20, working minutes – 480.

            Production – 550pcs. SMV – 6.20.

       So,

                                      550 X 6.20

        Efficiency = ------------------------------------------ X 100

                                    20 X 480

                         3410

              = ----------------------- X 100                          

                                  9600

                         = 35.52 %

Subject:   Calculation of Performance.

1. Wastage time or lost time.

v  When the operators done there work with rhythm in this time any incidental or accidental case operator wait for work. This called wastage time.

v  Such as, machine breakdown, behind operator work supply not properly, input problem, quality problem, electric failure, etc.

v  Wastage time starting & completed time write by operator her production sheet. However, approved by supervisor and responsible person.   

2. Operator performance.

v  One operator start her work with rhythm, if any case affect her work by wastage time, this is not her fault. So operator performance calculating time wastage time will be deducted from working time.

        Say,

             Working time – 480mts. Wastage time – 40mts.

            Production – 400pcs. SMV – 0.50.

           

    We know,

                                          Earn minutes

     Performance = ------------------------------------------------------   X 100

                                   Available minutes – Wastage minutes

         So,

                                                400 X 0.50

            Performance = -------------------------------- X 100

                                              480 – 40

                                           200

                                     = ------------- X 100

                                           440

                                     = 45.45 %

3. Team or line performance.

v  One line start work with rhythm, if any case affect some operators work by wastage time, this is not there fault.  

v  Considering total Lines affected operator’s wastage time.

     Say,

            No. of worker – 20, working minutes – 480, Wastage time – 2000mts.

            Production – 550pcs. SMV – 6.20.

So,

                                    550 X 6.20

Performance = -------------------------------- X 100

                               (20 X 480) – 2000

                                   3410

                        = ----------------------- X 100

                             9600 - 2000

                               3410

                        = ------------- X 100

                              7600

                         = 44.87 %

                     No. of operator x Working Hour

Target=--------------------------------------------------- X Expected Efficiency

                              S.M.V