Calculate Takt Time—Key Exercise

Basic Data Setup

Create Inventory Parts

Purpose: The purpose of this exercise is to show you how to create inventory parts to be used by a production line.

Windows:
Inventory Part

1. Open the Inventory Part window.
2. Create new inventory parts for your site, and enter the values shown in the table below.

2. Save the records.

Create Routings

Purpose: The purpose of this exercise is to show you how to create several alternative routings for the parts.

Windows:
Routing

1. Open the Routing window.
2. Create two routings for each part, one with the default alternative, where part 61–920 has an operation with the work center 910 (Operation 10), and another operation with the work center 920 (Operation 20).
3. Now create a second routing alternative. One for each part with similar operations, but vary the operation factors.
4. Make both routing alternatives buildable.
5. Create two similar routing alternatives where part 61–921 has one operation with the work center 910 (Operation 10), and another operation with the work center 920 (Operation 20).
6. Make these routing alternatives buildable.

Hint:  When creating routing operations, consider setting operation factors to meet a production rate goal for the products, e.g., 10 units per hour.  The goals should be in line with the anticipated demands for the products defined later in the exercise.

Create a Product Structure

Purpose: The purpose of this exercise is to show you how to create work centers to create a product structure.

Windows:
Product Structure

1. Open the Product Structure window.
2. Create a product structure where part 61–920 contains one piece of part  61–997.
3. Make the structure buildable.
4. Create a product structure where Part 61–921 contains contains one piece of part 61–997.  
5. Make the structure buildable.

Cost Calculation

Purpose: The purpose of this exercise is to show you how to create inventory value for the parts, so that the production receipt can be performed in later exercises.

Windows:
All Levels Part Cost Calculation

1. Open the All Levels Part Cost Calculation window.
2. Enter your site, the part 61–920, and the cost set 2.
3. Click OK.
4. To make the new cost calculation valid, right-click and then select Copy Costs to Cost Set 1.
5. Repeat the cost calculation for the part 61–921.

Create a Production Line

Purpose: The purpose of this exercise is to show you how to create a production line to be used with the production line management features.

Windows:
Production Line

1. Open the Production Line window.
2. Create a new record, and name the production line 909, with a description Production Line for Rims.
3. On the Part tab, add the parts 61–920 and 61-921.
4. Click the Schedule Attributes tab. Attach the horizon ID 7 to the part 61–901.
5. Save the record.

Receive Part into Inventory

Purpose: The purpose of this exercise is to show you how to receive material into inventory

Windows:
Receive Inventory Part

1. Open the Receive Inventory Part window.
2. Receive 50 parts of the part 61–997 into the location RLI.

Create Sales Parts

Purpose: The purpose of this exercise is to show you how to create a sales part in order to prepare for the demand.

Windows:
Sales Part

1. Create two sales parts corresponding to the top level parts 61-920 and 61-921. Make sure that the sales part number and the part number match.
2. Enter the values in the required fields.  Save your changes.

For more information on creating sales parts, see the exercise: Sales Part-Basic Data and Requirements Exercises  

Create a Customer

Purpose: The purpose of this exercise is to show you how to prepare the demand to be used in the Production Line Management exercises.

Windows:
Customer

1. If you have not already done so for another exercise, create a new customer. Enter the values in the required fields.
2. Save your changes.

For more information on creating a customer, see the exercise: Customer-Basic Data and Requirements Exercise

Create a Customer Order

Purpose: The purpose of this exercise is to show you how to prepare demands to be used in the Production Line Management exercises.

Windows:
Customer Order

1. Create a customer order with a series of order lines spanning a range of future dates.
2. Create several demands for the parts 61-920 and 61-921.  It is suggested that the demand quantities vary somewhat over time, but not dramatically so.
3. Release the customer order.

For more information on creating a customer order, see the exercise: Entering Customer Order - Exercises

Main Exercise

Purpose: The purpose of this exercise is to show you how takt time calculation works with production line management.

Windows:
Production Line Management

Specify Line Operating Parameters

1. Open the Production Line Management window.
2. Query for the production line 909.
3. Enter 7 in the Default Scheduling Horizon field; this value is used for each part on the production line.
4. On the Takt Time Calc tab, enter a value in the Daily Operating Minutes field to describe how long the line runs each day. For example, 480 minutes = 8 hours.
5. Save your changes.

Retrieve Demand

1. Right-click and then click Retrieve Demand. Specify a date range of the demand that you want to sample. Select the Customer Order check box as the demand source from which you want to retrieve.
2. Click OK.
3. Click the Demand Details tab, and check the results.

Calculate Takt Time

1. Right-click and then click Calculate Takt Time.  Specify a date range of production line demands to sample.
2. Click OK.
3. Click the Takt Time Calc tab, and check the results in the Production Line Takt Time and Average Daily Demand fields.

Compare Takt Time to Line Routings

1. Right-click and then click Routing Operation and Load Analysis Parameters.
2. For each part on the line, specify a routing alternative to use for this comparison.  Also specify your choices for calculating the operation duration from the operation information. Optionally, specify a production lot size to be used (e.g. kanban size).
3. Click OK.
4. Click the Operation Analysis tab, and check the results.  For each part displayed in the upper table, check the operation duration times that have been calculated. Also, check the graphical display in the lower right pane, comparing the line takt time with the currently selected routing alternative. Re-calculate using a different routing alternative or calculation factors if desired.

Set Production Line Rate

1. Right-click and then click Set Production Line Rate.
2. In the dialog box that opens, the calculated average daily demand for the line is used as the default production line rate. You can adjust this quantity if you want. The effectivity date is used by default as the demand sample start date.
3. Click OK.
4. Click the Line Rates tab, and check the results.