In the middle of producing manufacturing parts and intermediate products within the factory, if production of intermediate products sometimes fails to meet the planned number due to the occurrence of troubles such as brief stop, there is a case that intermediate products be purchased from outsourcing in order to achieve the targeted shipment number of final products.
In other cases, considering the pre-process capability of the company and the targeted number of production, some parts may be purchased from outside without manufacturing themselves.
In this case, we simulate the process of manufacturing in-house parts and the step of producing outsourced parts together, and let's examine the issue of how many parts are to be produced internally against the post-process.
1. Change of Model
First, we examine this issue by utilizing the sample model.
Open "サンプルプロジェｔクト_仕事の構造発想法_工程プラン立案(Sample Project _ Structured Idea of Work _ Process Planning)".
In this model, there is "Process plan 1" (the left side of process flow), which is considered as the case of in-house processing this time. The process plan for in-house production is as follows.
On the other hand, this model has "Processing plan 2" (the right side of process flow), which is considered as a process to manufacture from intermediate products purchased from outside. In addition, this plan has a process which is necessary for sub-contracting process called machining process.
Moreover, in this model, there is a transport carried by a worker which is connecting between processes.
Set the operation time for this worker in the operation time master.
In this setting, we assume 8:00am – 17:00pm as working time of a day, 12:10pm – 13:00pm as a lunch break, and 10 minutes at 10:00am and 15:00pm as each small break.
2. Verification of the results only in-house production is produced.
In the modified model, the plan for in-house production is set by default.
Let's start with the volume of this plan.
We aim to produce 100 pieces per day.
While watching this result above, you can find that 100 pieces are produced at 16:47:05.
3. Verification of production when outsourcing is included
Next, let's see how if you do outsourcing in order to achieve the goal of producing 100 pieces per day.
While looking at the time required for each process plan, the process of completing all in-house production is originally the best, but we try to verify the process capability when production from outsourced items is required.
In the production rendering setting panel, we create a plan with the changed target value.
We see the results with this setting after rendering.
In production from outsourced items, we found that we can produce 26 pieces per day.
4. In-house Production: Examination of Outsourcing Number
Then, mix the production from the in-hose product and the outsourced product, simulate them, and see how many outsourced items are needed to achieve 100 pieces of production.
As it turned out that it is possible to produce up to 26 pieces when only the outsourced item was produced earlier, we set up plans to produce each one alternately with this as the goal.
Let's see the rendering results.
You can find that you cannot achieve production of 100 pieces per day.
Here, let's try rendering by changing the target number of processing plan 1 and processing plan 2 to various values.
Here, it was found that the target number of 100 pieces can be achieved when the target number of processing plan 1 is set to 97 and the target number of processing plan 2 is set to 3.
In other words, at minimum, 97 in-house parts are required, and if it falls below this value, even if it is covered with outsourced items, it will not reach the target of 100 pieces. Therefore, it is necessary to consider production, for example, another improvement plan.
In this way, by sequentially simulating the production plan according to the daily situation, it is possible to identify whether the examination of improvement plan or its effects can be applied to the actual production by confirming the problems in the production in advance.
Such utilization method is effective in order for flexible production according to daily production.
Please use it by all means.
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