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Flow Time Slides

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9/28/2015

Flow-Time Analysis
Competitive Advantages of a shorter flow time
– Shorter response time (both in production and product design)
• Easier to respond to market changes
• Fast feedback on quality problems
• Delayed differentiation (Postponement)

– Lower inventory costs (due to Little’s Law)

Processing
System

Inputs

Outputs

Flow Time Analysis

T Flow time = processing time + wait time (total time in the box)
Presentation by Adam Fleischhacker
Assistant Professor of Operations Management
JP Morgan Chase Scholar
University of Delaware

Theoretical Flow Time is the time to process a typical flow unit assuming NO waiting.

Wondershed Inc. : Schematic
Representation

Flowcharting
Activity

-

Buffer

Decision

Physical flow
Event

Punch base Form base Punch roof Form roof Information flow

See the total process; a systems view
Define flow units and process boundaries
Include only the key steps
Clarify the level of detail needed. Processes can be broken down into sub-activities. On the other hand, cascading allows several activities to be combined in a single sub-process
- Depicts resources required to carry out activities
- Identify the processes that need attention (weak points)

Start

Start

Sub assemble base Separate
Sheet

Activity
A

Activity
B

Activity
C

Assemble

Inspect

End

End

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Wondershed Inc. Theoretical Flow Time

Finding Theoretical Flow Time Sequential & Parallel
Path 1: 1-3-5-7-8 (T1=80)

Activity Times at Wonder Shed Inc.
Activity

Activity Time
(minutes)

1

Separate
Punch the base

25

3

Punch the roof

20

4

Form the base

5

5

Form the roof

10

6

Subassemble the base

10

7
8

Assemble
Inspect

5
(10)

10

2

3
(20)

10
30

Start

7
(10)

1
(10)
2
(25)

T   max(T 1 , T 2 )  90

Path 1 (roof) Start  1  3  5  7  8  End

= 90 minutes

Observations about Critical Path
• Delaying an activity on CP will increase T*
• Activities NOT on CP can be delayed to some degree without increasing T*
• Speeding up activities on the CP will decrease T*
• Speeding up activities NOT on the CP will NOT decrease T*
• The CP can change as we change the activity times • We are still assuming the activity times are known deterministic quantities (no randomness)

Finish

6
(10)

Path 2: 1-2-4-6-7-8 (T2=90)

T* is the length of longest path through the process
The path associated with T* is called the Critical Path
Activities on the Critical Path are called Critical Activities

= 80 minutes

Path 2 (base) Start  1  2  4  6  7  8  End

4
(5)

8
(30)

Direct & Indirect Methods of
Measuring Flow Time
Direct Method


Observe a process over an extended, specified period of time



Randomly sample flow units over the observation period



Measure the flow time for each flow unit from entry to exit



Compute the average of flow times measured

Indirect Method


Count the number of units produced over an extended period of time



R = number of units produced / duration of time period



Count the number of units of inventory at random points during the time period, and compute the average inventory (I).



Compute T =I/R

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Indirect Method for Waiting Times Example
What is the average waiting time for a roof?

What is the average waiting time for a base?

Theoretical flow times
Roof 80 minutes
Base 90 minutes
What are the average flow times(waiting + activity)?
Roof ??? + 80 = ??? minutes
Base ??? + 90 = ??? minutes

16.5 sheds average flow rate (R) per hour based on empirical data
Average Average number of number of bases roofs
Buffer
2
30
3
25
4
10
5
20
6
20
7
10
15
8
20
20
Total
90
80

Value-adding vs. Non-valueadding activities
Value-adding activities are those activities that increase the value of a flow unit
– Example: assembly, surgery, piloting an airplane, etc. Non value adding activities are activities that do not directly increase the value of a flow unit.





Re-work
Transport
Inspection
Waiting

Flow Time Efficiencies in White
Collar Processes
Industry

Process

Average
Flow Time

Theoretical
Flow Time

Flow Time
Efficiency

72 hrs.

7 min.

0.16%

Consumer Packaging New Graphic
Design

18 days

2 hrs.

0.14%

Commercial Bank

Consumer
Loan

24 hrs.

34 min.

2.36%

Hospital

Patient Billing

10 days

3 hrs.

3.75%

Automobile
Manufacture

Financial
Closing

11 days

5 hrs

5.60%

Life Insurance

New Policy
Application

Reducing Theoretical Flow Time: Shorten the Length of Every Critical Path by 3 Basic Approaches
 Eliminate: Reducing the work content of critical activities

– Work smarter: Eliminate non-value-adding aspects of the activity:
– Work Faster: Increase the speed at which the activity is performed, e.g. Better Methods, Training, Advanced
Technology, Better Management.
– Work right in the first time: Reduce repetitions of the activity  Work in parallel: Moving work off the critical path

– Move work off the critical path to a noncritical activity
– Move work off the critical path to the outer loop (pre- or post-processing)  Select: Modify the product mix

Flow time = Value-adding times + Non-value-adding times

– Make more of a product that requires less processing time  reduce overall flow time (Given market condition)

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Activities on Node (AON): Network
Diagram to show precedence

More Examples of AON Network

A
A

B

C

C

A comes before B which comes before C

B
A and B must both be completed before C can start

13

AON Example: Milwaukee Paper
Activity
A

Description
Modify roof and floor



C

Construct collection stack

A

D

Pour concrete and install frame

A, B

E

Build high-temperature burner

C

F

Install pollution control system

C

G

Install air pollution device
Inspect and test

F, G

Description
Build internal components
Modify roof and floor
Construct collection stack
Pour concrete and install frame
Build high-temperature burner
Install pollution control system
Install air pollution device
Inspect and test

Immediate Activity Duration
Predecessors
(weeks)

2

3
A
2
A, B
4
C
4
C
3
D, E
5
F, G
2
Total Time
25
(weeks)

D, E

H

Activity
A
B
C
D
E
F
G
H



B

AON Example: Milwaukee Paper
CPM Notes (Can we finish in 16 weeks?)

Immediate
Predecessors

Build internal components

14

15

16

4

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AON Network for Milwaukee Paper

AON Network for Milwaukee Paper
Activity A Precedes Activity C

A

Activity A
(Build Internal Components)

A

B

Start

Start
Activity

C

D

Start

B

Activity B
(Modify Roof and Floor)

Activities A and B
Precede Activity D
17

18

Determining the Project
Schedule

AON Network for Milwaukee Paper

Perform a Critical Path Analysis
F
A

• The critical path is the longest path through the network

C

• The critical path is the shortest time in which the project can be completed

E

Start

H

• Any delay in critical path activities delays the project
B

D

G
• Critical path activities have no slack time

Arrows Show Precedence
Relationships
19

20

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Determining the Project
Schedule

Determining the Project
Schedule

Perform a Critical Path Analysis
Activity
A
B
C
D
E
F
G
H

Perform a Critical Path Analysis

Description
Time (weeks)
Build internal components
2
Modify roof and floor
3
Construct collection stack
2
Pour concrete and install frame
4
Build high‐temperature burner
4
Install pollution control system
3
Install air pollution device
5
Inspect and test
2
Total Time (weeks)
25

21

Determining the Project
Schedule

Forward Pass
Begin at starting event and work forward

Perform a Critical Path Analysis

Earliest Start Time Rule:

Activity Name or
Symbol
A

Earliest
Start

ES

Latest
Start

LS

EF

LF
2

Earliest start (ES) = earliest time at which an activity can start,
Activity
Description
Time (weeks) assuming all predecessors have been
A
Build internal components
2
completed
B
Modify roof and floor
3
Earliest finish (EF) = earliest time at which an activity can be finished C
Construct collection stack
2
D
Pour concrete and install frame
4
Latest start (LS) = latest time at which an activity can start so as to not delay the completion time of the
E
Build high‐temperature burner
4
entire project
F
Install pollution control system
3
Latest finish (LF) = latest time by which an activity has to be
G
Install air pollution device
5
finished so as to not delay the completion
H
Inspect and test
2
time of the entire project
Table 3.2
Total Time (weeks)
25
22

 If an activity has only one immediate predecessor, its ES equals the EF of the predecessor  If an activity has multiple immediate predecessors, its ES is the maximum of all the
EF values of its predecessors

Earliest
Finish

Latest
Finish

ES = Max (EF of all immediate predecessors)
Activity Duration

23

24

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ES/EF Network for Milwaukee Paper

Forward Pass

Begin at starting event and work forward
ES

Earliest Finish Time Rule:

EF = ES + Activity time
Start

 The earliest finish time (EF) of an activity is the sum of its earliest start time (ES) and its activity time

0

0

0

EF = ES + Activity time

25

ES/EF Network for Milwaukee Paper

Start

0

ES/EF Network for Milwaukee Paper

EF of A =
ES of A + 2

ES of A
0

26

0

A

0

A

2

2

0

0

Start

0

0

2

EF of B =
ES of B + 3

ES of B

0

B

3

2
3
27

28

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9/28/2015

ES/EF Network for Milwaukee Paper
0

A

2

2

2
0

Start

C

ES/EF Network for Milwaukee Paper
0

4

A

2

2

2

2

0

0

0

Start

0

C

4

2

= Max (2, 3)

D

0
0

B

3

3

0

3

B

7

3

3

4

29

ES/EF Network for Milwaukee Paper
0

A

2

2

2
0

Start

C

30

ES/EF Network for Milwaukee Paper
0

4

A

2

2

2

2

0

0

0

Start

C

B

3

3

3

D

7

0

4

B

3
31

7

E

8

13

3

3

D

4

7

H

15

2

4
0

4

F

3

2

0
0

4

4

8

G

13

5
32

8

9/28/2015

Backward Pass

Backward Pass
Begin with the last event and work backwards

Begin with the last event and work backwards

Latest Finish Time Rule:

Latest Start Time Rule:

 If an activity is an immediate predecessor for just a single activity, its LF equals the LS of the activity that immediately follows it
 If an activity is an immediate predecessor to more than one activity, its LF is the minimum of all LS values of all activities that immediately follow it

 The latest start time (LS) of an activity is the difference of its latest finish time (LF) and its activity time

LS = LF – Activity time

LF = Min (LS of all immediate following activities)
33

34

LS/LF Times for
Milwaukee Paper
0

A

2

2

2
0

Start

C

4

4

LS/LF Times for
Milwaukee Paper
F

7

4

0

E

8

13
13

4
B

3

3

LS = LF – Activity time
D
3

7

4

8

G

5

A

2

2

2

3

2

0

0

0

H

2

15
15

0

Start

LF = EF of Project

10

F

3

7
13

E

4
LF = Min(LS of 8 following activity)

0

13
13

4
B

3
35

4

4

2

0

0

13

C

3

3

D

4

7

8

G

H

2

15
15

13

5
36

9

9/28/2015

LS/LF Times for
LF = Min(4, 10)
Milwaukee Paper
0

A

2

2

2
0

Start

2

C

2

4

4

4

10

0

4
4

0
0

B

3

3

3

D

4

7

E

4

LS/LF Times for
Milwaukee Paper
F

3

7

0

13

0

8

13

8

13

8
8

G

5

H

2

15

0

15

0

Start

0

13

2

2

2

2

2

C

2

4

4

4

10

0

4

0

4

0

13

A

1

B

3

3

3

4

4

D

4

E

4

F

7
13

3

8

13

8

13

7

8

8

8

G

H

2

15
15

13
13

5

37

38

Computing Slack Time

Computing Slack Time
Activity

 Slack is the length of time an activity can be delayed without delaying the entire project

Slack = LS – ES or Slack = LF – EF

39

Earliest
Start
ES

Earliest
Finish
EF

Latest
Start
LS

Latest
Finish
LF

Slack
LS – ES

A
B
C
D
E
F
G
H

After computing the ES, EF, LS, and LF times for all activities, compute the slack or free time for each activity 0
0
2
3
4
4
8
13

2
3
4
7
8
7
13
15

0
1
2
4
4
10
8
13

2
4
4
8
8
13
13
15

0
1
0
1
0
6
0
0

On
Critical
Path

Yes
No
Yes
No
Yes
No
Yes
Yes
40

10

9/28/2015

Critical Path for
Milwaukee Paper
0
0

0
0

Start

0

A

2
2

2

C

2
2

2

4

4

10

4

0

4

0
1

B

3
4

3

D

3
4

4

F

4

0

E

4

ES – EF Gantt Chart for Milwaukee Paper
3

1

7
13

13

8

13

8

G

8
8

5

3

4

5

6

7

8

9

10

11 12 13 14

H

2

C Construct collection stack

15

D Pour concrete and install frame 15

E Build high‐temperature burner F Install pollution control system 13

G Install air pollution device

13

H Inspect and test

41

LS – LF Gantt Chart for Milwaukee Paper
1

2

3

4

5

6

7

8

9

10

15 16

B Modify roof and floor

8

7

2

A Build internal components 11 12 13 14

42

Put Learning Into Action
15 16

A Build internal components B Modify roof and floor

• Rock Band Simulation
• SCRUM Video

C Construct collection stack
D Pour concrete and install frame E Build high‐temperature burner F Install pollution control system G Install air pollution device
H Inspect and test

43

11

9/28/2015

Upcoming Schedule
• Next Week: EFFICIENCY: Flow – Flow
Rate and Capacity Analysis (Ch. 5)
• HW is available on CANVAS
• Have a great week!

12

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