Calculating Manufacturing Lead Time—Exercises

IMPORTANT
It is extremely important that you set up and work within your own site to maintain your data integrity. If you work within any other site, you will compromise your own exercise data as well as the data of other students. Predictable exercise results require that your data be isolated in your own site.

Required Data

Creating Routing

Purpose: The purpose of this exercise is to show you how to set up the basic data required for running this particular functionality.

Windows:
Routing
Note: If you already have a routing for the Fuel System Part 20–250 in your site, use your existing routing.

  1. Open the Routing window.
  2. Create a routing for Part 20–250.

General exercise for Creating Routing

Entering Purchase Lead Time

Purpose: The purpose of this exercise is to show you how to set up the basic data required for running the cumulative lead time calculation.

Windows:
Inventory Part/Acquisition
Note: If you already have purchase lead time data for your purchase part on your site, use your existing parts.

  1. Open the Inventory Part window, and click the Acquisition tab.

  2. In the Purchase Leadtime field, enter the information shown in the table below. Save (F12) after each entry.

Part No Purchase Leadtime
20–350 10
20–352 15

Main Exercises

Purpose: The purpose of these exercises is to show you how to calculate the manufacturing and cumulative lead times.

Windows:
Lead Time Calculation
 Cumulative Lead Time Calculation
 Routing
 Inventory Part/Acquisition tab
 Inventory Part/Manufacturing tab

Note: IFS Racing has entered its manufactured parts with their structures and routings. You need to update the calculated lead time for the parts.

Note: If only one site is entered and you leave the Part No field blank, you will perform the calculations for the whole site.

Calculating Manufacturing Lead Time

  1. Open the Lead time Time Calculation window.
  2. In the Part No field, enter the part number on your site.
  3. Calculate the maximum of machine and labor lead time, and keep the default settings, i.e., the capacity is Average and the no-routing option is Leave Unmodified.
  4. Click OK to order calculation.
  5. Open the Inventory Part window, and query for Part 20–250.
  6. Click the Acquisition tab and then the Manufacturing tab. Note the results in the lead time fields.

Note: You have now performed a general manufacturing lead time calculation. To calculate a specific lead time for a part and simulate the effect of lot size on lead time, continue with the steps below.

  1. Open the Routing window, and query for Part 20–250.
  2. In the Routings tab, change data in the Mach Setup Time field by entering 10 for the first operation.
  3. In the header portion of the Routings tab, right-click and then click Calculate Manuf Lead Time.
  4. Calculate the maximum of machine and labor lead time without changing the lot size.
  5. Click OK to order  calculation.
  6. In the header portion of the Routings tab, analyze the results in the lead time fields. You can see that the fixed values are affected. 
  7. Change the value in the Mach Run Factor field by entering 5 for the first operation. 
  8. Repeat the calculation as described without changing the lot size
  9. In the header portion of the Routings tab, analyze the results in the lead time fields. You can see that the variable values are affected. 
  10. Simulate the change of lot size. Calculate the maximum of machine and labor lead time, and set the lot size to 10.
  11. Repeat the calculation as described above with a different lot size.
  12. In the header portion of the Routings tab, analyze the results in the lead time fields. You can see that the lot sizes values are affected.

Note: After calculating lead times for the part, and the routing alternative is something else but star (*), you might want to change it permanently. To do so, continue with the following steps. If the routing alternative is star (*), then the changes of the inventory part record happen automatically in the previous exercise.

  1. Open the Routing window, and query for Part 20–250.
  2. When calculating the lead time as described, select Update from the Update Options list.
  3. Review the results in the Inventory Part window. Query for Part 20–250.
  4. Click the Acquisition tab and the Manufacturing tab. Analyze the results in the different lead time fields.

Calculating Cumulative Lead Time

  1. Open the Cumulative Lead Time Calculationwindow.
  2. In the Part No field, enter the part number on your site. 
  3. Click OK to order calculation.
  4. Open the Inventory Part window, and query for Part 20–250.
  5. Click the Manufacturing tab, and analyze the results in the Cum Leadtime field.

Note: When changes to manufacturing lead time have been made as described in the Calculate the Manufacturing Lead Time exercise, perform the steps below.

  1. Open the Routing window, and query for Part 20–250.
  2. In the header portion of the window, right-click and then click Change Cumulative Lead Time.
  3. Click OK to order change.
  4. Open the Inventory Part window, and query for Part 20–250.
  5. Click the Manufacturing tab, and analyze the results in the Cum Leadtime field.