Make assumptions and calculations to reduce the cycle time and changeover time of these operations, in the table you can see the 12 operations, just make calculations to improve the CT of operations 2 and 6 and give a solution to reduce the CO time in operation 6.

what method and calculations can be used to improve and reduce Cycle time and changeover time of operation:

for example, I have in a manufacturing process I have milling 2 operation, the milling operation has 4 machines it's cycle time: 14.08 min it has 3 shifts, its performance: 80%, availability: 90%, quality: 70%, OEE= 50.40%.

another operation honing operation has changeover time = 30 min, CT=10.9 min, shifts =3, preformance= 85%, availability= 81%, quality is 69%, OEE= 47.50%

Monthly: 3000 ordered per month

Shift: 3

Main Industry Work Plan:

- 27 working days a month.

- All production units work 3 shifts.

- Each shift is 8 hours.

There are two 15-minute breaks in the shifts and one 30-minute meal break.

Takt time of the whole operations and manufacturing process is 12.15 min.

the lead time of the whole process is 56,73 min.

in the process, there are 12 operations. I want to improve milling 2 and honing process

Milling1 produces 252 parts per day, milling 2 with four machines 458 parts per day, leveling 362 parts per day, heat treatment 262 parts per day, quality control 1 produces 1260 parts per day. Normally, the company should produce 111 parts according to their order plans, but these operations produce much more, making overstock.

In the honing operation, 115 pieces were produced per day.

Operation	number of machines	CT (min)	unit/hr	CO	Shifts	performance	Availability	Quality	OEE	intermediate stock	Capacity/hr
1- Milling	1	5	12.00		3	57.00%	83.00%	50.00%	23.66%	1000	2.84
2- Milling 2	4	14.08	1.07		3	80.00%	90.00%	70.00%	50.40%	162	0.54
3- Leveling	3	6.96	2.87		3					178	0.00
4- Heat Treatment	1	4.8	12.50		3	85.00%	95.00%	85.00%	68.64%	0	8.58
5- Quality Control	1	1	60.00		3					50	0.00
6- Honing	1	10.9	5.50	30 min	3	85.00%	81.00%	69.00%	47.50%	152	2.61
7- Temper Furnace	1	1.39	43.17		3	85.00%	85.00%	80.00%	57.80%	0	24.95
8- Sandblasting	1	2.32	25.86		3					0	0.00
9- Coating	1	1.45	41.38		3					0	0.00
10- 'H'Embrittlement Furnace	1	2.78	21.58		3	72.00%	95.00%	95.00%	54.72%	0	11.81
11- Quality Control 2	1	6.05	9.92		3					0	0.00
12- Delivery to Warehouse	2	5	6.00		3					0	0.00

Answer rating: 100% (QA)

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