Learning Curves

Learning Curves
Learning curves: the time required to perform a task decreases with increasing repetitions

Learning Effect
Time per repetition

Number of repetitions

Learning with Improvements

Time per unit

Average

Improvements may create a scallop effect in the curve.

Time

Applications of Learning Curves

1.Manpower planning and scheduling 2.Negotiated purchasing

3.Pricing new products

4.Budgeting, purchasing, and inventory planning 5.Capacity Planning

Worker Learning Curves

Time/cycles

A (underqualified) B (average)

Standard time
C (overqualified)

One week

Training time

Cautions and Criticisms

Learning rates may differ from organization to organization
Projections based on learning curves should be viewed as approximations Estimates based the first unit should be checked for valid times

Cautions and Criticisms

At some point the curve might level off or even tip upward Some improvements may be more apparent than real For the most part, the concept does not apply to mass production

Manufacturing Systems

Components of Manufacturing System

Production Machines Material Handling System Computer Control System Human Resources

Facility Layout
Which comes FIRST, the material handling system or the facilities layout? Layout is effected by:
Centralized vs. Decentralize Storage of WIP, Tooling,

& Supplies Fixed Path vs. Variable Path Handling Unit Load Size Degree of Automation Type and Level of Inventory and Control of Materials

Facility Layout and Material Handling

Handling less is BEST Number of times handled may be more important than distance Layout or MHS First ? -- BOTH Sequential approach which considers a number of alternative handling systems and the corresponding layout alternatives.

Modular Design Concepts

Facility Re-layouts can be caused by Changes in the design of an existing product or in the product set to be produced. Changes in the production sequences or in the processing equipment. Changes in the production quantities and schedules, which prompt capacity changes. Changes in organizational structure or management philosophy. Changes in requirements for space, equipment, and people.

Modular Design Concepts

Flexibility achieved by: Modular office equipment Modular workstations Modular material handling equipment General purpose production equipment Expandability of the total system design

Modular Facilities
Use of an interconnecting spine for material transport and movement of people. Standard size modules to allow functions to be interchanged if relationships change. Expand by extending the spine and adding modules -- creates minimal disruption to the existing facility. Alternative spine configurations: straight line, "T", or "X".

Modular Material Handling

Plan flexible, standardized systems for handling, storing, and controlling material within the facility. Build in flexibility. Standardize methods: unit loads, equipment, etc. Integrate into a system as opposed to separate pieces serving only part of the facility.

Classification of Manufacturing Systems

Types of Operations Performed Number of Workstations Automation Level Part of Product Variety

Classification Scheme
Type I Single Stations Type II Multi-Station Cells Type III Production Lines