UNBALANCED LOADS

1
UNBALANCED LOADS

• Bain AND Boon
• To Inventory Management

2
The Classic Unbalanced Load

• Usually, when you want one of these

3

• You have to buy it in this unit lot size

The typical 8 hot dog package!
4

• AND if you would like to have it served in a bun
  with the usual condiments,

5

• You would need to buy the buns in lots of

TEN!?!?!
6

• Or an even bigger lot of

TWELVE BUNS!?!?! For 1 hot dog?????
7

• Doing the math shows that to balance
• the loads involved would require

3 packages of hot dogs 24 hot dogs 2 packages
of 12 buns 24 buns
OR
5 packages of hot dogs 40 hot dogs 4 packages
of 10 buns 40 buns
Not exactly always feasible or desirable not
to mention costly and wasteful!
8
Machined Parts Connections

• The same situation exists with machined
• parts and / or products as well as with
• most any manufactured items.
• The following slides use a flow-through
• machined part process as an example.

9
Machined Parts Relationship

• In working with machined parts or products,
• the same situation becomes an every day
• occurrence as raw parts come in to
• the machining area and go
• out as completed parts.

Many different lot sizes come into play in order
to allow for proper processing. All of these lot
sizes are good for the area in which they are
worked but not always good for the last or next
work station in their travel to completed part!
10

• WARNING!!!!!
• Not all parts in a machining area are equal in
  lot
• sizes, processing procedures or in part demands!
• In the interest of both time and explanations,
• the parts and situations used here are NOT
• specific nor intended to be.

11

• Raw parts arrive in house in crate lots

This is not only our first lot quantity but our
first part number also each area will receive a
part number lot quantity for the machines in
area.
12

• A typical crate lot will have 1400 parts inside

While these are all the same part number, the
quantity to be worked may need to change to allow
for a sensible production run size in Machine
Area 1.
13

• These crate lots will be worked in the
• Machine Area 1
• in quantities that will be made equal to a
• HALF FURNACE LOT
• or roughly 700 pieces
• BUT this will require scheduling efforts to reach
• the desirable number of parts for a
• FULL FURNACE LOT
• AND to get a desirable Area 1 Lot Run
• quantity which bests uses the equipment!

14

• Post-Area 1 parts are collected in baskets--
• In our example 140 pieces per basket

These items now have their own part number and
have completed a work order they will get a new
work order to track their progress through the
process.
15

• These parts again need to be re-packaged
• in Area 2 in order to meet all of the
• requirements of getting a full lot into
• the furnaces ---- OH, remember that a single
  Area
• 2 Lot is NOT a desirable Area 1 Lot!!! This
  quantity
• situation repeats throughout all of the process
  areas!

Each new area receiving parts gets a new computer
work order number AND matching shop floor control
order to process. Lot sizes for parts in our
example currently reflect the one lot size that
should / can not change
the AREA 2 LOT quantity!
16

• A Half Area 2 Lot post-furnace work, about 700
  parts

Another part number and another completed work
order building up lot numbers.
17

• Yes, the Area 2 Lot must also be repackaged!
• This time, the parts are lot sized for Area 3.

Sorry, but those clean neat racks need to stay in
Area 2! These bins work better out here on the
work floor by Area 3 for all concerned!
18
Lot Sizing Information Break

• Each re-sizing of the product lot allows the
• different work areas to properly process the
• parts and move them efficiently in the Machining
  work area.
• All lot sizes play important roles in the
  work processes!

19

• After Area 3, the parts are again put into
  baskets
• this time prior to Area 4 in flexible
  quantities.

FLEXIBLE? The Area 4 Lot requires no
set amount of parts to get the best return for
the work that is performed. This allows for
speedy response to needs if necessary!!
Yet ANOTHER part number and ANOTHER work order
assigned here to help the area track the part
builds.
20

• After Area 4, the parts are re-racked then
• sent to Area 5 prior to final packaging.

Note Some Pictures Repeat To Ease In Flow!
Area 5 parts also get their own part number.
New work orders also.
21

• After Area 5, the parts are cleaned, treated and
  racked prior to packing out for warehousing.

While this LOOKS like another lot size, IT ISNT!
By this time, the parts have been in 6 different
lot sizes across 5 different work areas. Just 1
to go!
22

• Finally, the parts are packed out for the
  Warehouse and receive their final lot size of
  780 pieces.

This is the final part number on the final work
order, which is how the part travels to its NHA,
or Next Higher Assembly to Machining Area THAT
is the Customer!
23
The BAIN Part of the Equation

• Multiple lot sizes across the work floor for the
• different processing equipment areas
• Multiple associated part numbers in the same
  family part group with own lot size
• Multiple work orders to control in unequal
  multiples of lot sizes if necessary
• Overlap of lots area to area during processes
• NOT ALL AREAS RUN AT SAME SPEED!!

24
The BOON of the Equation

• Multiple lot sizes allow for best use of each
• sections processing equipment
• Flexibility with shifting priorities achieved
• Movement of parts made in safe, consistent
  manageable quantities
• Work order builds can be done in lots of
  smaller bites instead of large CHUNKS
• Guesswork in quantities time to build GONE
  for everyone involved!

25
Hot Dogs to Final Parts? It means

• You may have to do lots to satisfy your
  Customers hunger!

26
LOTS OF QUESTIONS??