Production Capacity Chart ‘This chart determines the capacity of the machines in a process. It doc uments machine and manual times and allows us to identify bottlenecks at a glance. Production capacity for a given machine is calculated using the fol= lowing formula: Capacity = Operational trae per shift + (Process time ++ Setup time interval) Setup time refers te the time required to change from one machine setting to another. Setup fer 2 punch press might include changing the die, adjust= ing the machine settings and loading a new coil of steel. The interval refers to the frequency of setup in terms of number of parts. Figure 4.2! shows an actual chart. The production capacity of the drilling machine used in process 2 may be calculated as follows: *+ Operational tme = 460 minutes per shift 27,600 seconds) + Process time = 24 seconds per part. Uattipe 25 Son See) ee ae es Sa ar oe a [ce poewtana) ie |e) se el ieerae Tse Ymes | = i Figure 4.2. Production Capacity Chart+ Time needed to replace grinding wheel ~ 30 seconds. + Interval = every 1,000 pars, Solution: Capacity = 27,600 seconds +(24 + 30/1000) = 1,148.5 parts The capacity of the drilling machine is 1.148 parts per shift. Standardized Werk Combination Table This chart shows: + Work elements and their sequence + Time per work element. * Operator and machine time. + The interaction between operators and machines or between different operators The chart makes kaizen easier by breaking down the movements of the operator and relating them to machine time. Figure 4.3" shows an actual chart. rer ereue then [ou Pe Sun cEnd of acto) [walang Sra €0dy Re Doo Pike roe ss gO wera 1 AE | tens | fs Nay 8/03 |S 0 | Pick See (End of Masti) Load Sen Hem taenine Pree St secon instal cb ts0y 19 8 Pie Er Se aad Fr iy [Fie x Sin aa Ry Sian ve te ine instal Weld Ne Load assysie TET ic Feme and Hinge Sd neal eamretnge Sd «5 ig ie Sab A65) Hinge PiiWeld oush gat o iz 8 afolwlo|u|= [im s/s) Bus SSSSe PERSE | BEE] Figure 4.3. Standardized Work Combination TableStandardized Work Analysis Chart ‘This chart helps to rationalize layout and to tain workers. It comprises: * The work layout. + Process steps and times. * Critical quality and safety items, * Standardized WIP stock. Figure 4.42” shows an actual chart, (or aincead strom | [a Sie he uci | Pe t-aconby ea 8 EP S.A Pee cin aaa Sen ec sn Las Sin ek ner at 5/30 a crime and ge Se Ina rane ice Se Lt ge deg jt suas ngs Sal eras car eee) BS SOM SM Sco gag TCPRRERGCE S-RED | | L eRe Te OT weed Figure 4.4. Standard Work Analysis Chart