Guidelines for operations & routings

About workcenters

 No process in Trèves is completely automatic. That means that, in all machines, closed to the
machine time, there will be always labor time associated
 And in the opposite way, in front of all the manual operations, there will be a machine time
associated; corresponding to the concept of the surface used during the operations, to take in
counts the cost of energies, renting, maintenance…
 We need to understand which kind and how many workcenters are assigned to each one of the
processes
o Which kind:
 If the workcenters are basically linked with a machine concept. These
workcenters will have machine capacity as main capacity (this will be the
scheduling capacity)
 Or if they are linked with manual operations (even if they are done by small
production tools). These workcenters will have as main capacity the labor one
(the scheduling one)
o How many workcenters for the process:
 We can have only one workcenter. If that is the case, all the operations, even the
finishing ones should be incorporated in the routing at once, to avoid duplicating
machine times overpassed (we will include all the manual operations within the
same machine time).
 Or we can have multiple workcenters, focus in the machine process and focus in
the manual operations. In this case, we’ll breakdown the different processes
(paying attention not to double machine times).
 If we need to isolate the different capacities or KPI’s for operations / machines, we’ll need to
have different workcenters to disaggregate these operations.
 If we need to isolate the different capacities or KPI’s of finishing operations, we’ll need to have
those operations disaggregated in different workcenters.
About routings
We need to define the base quantity, the labor time and the machine time

 Continues Process: complexing process, aiguilletage, review tables…

o The process is commanded by the machine time
o Base quantity: the economical batch in meters
o Machine time: the real time to produce the economical batch meters
o Labor time: machine time by the number of operators working in the process
o The changes and tpm activities should be incorporated in the efficiency ratio
o Number of individual capacities: 1 (each machine will be one)
 Cutting (lectra process):
o Base quantity: the economical batch in sets
o Machine time: the real time to cut the layers. The preparation of the layers is a hidden
operation, so not to take in count. As well, the packaging or controlling
o Labor time: machine time by the number of operators working in the process
o The changes and tpm activities should be incorporated in the efficiency ratio
o The overproduction by batch will be part of the efficiency ratio
o Number of individual capacities: 1 (each machine will be one)
 Presses, assembly machines, gluing stations, stamping:
o Base quantity: the number of identical parts (identical cavities) by cycle of the press
o Machine time: corresponding to the cycle time. The time corresponding to:
 Start cycle bottom (or signal)
 Close machine time
 Opening of the press
 Unloading parts
 Loading material
o Labor time: the cycle time machine by the number of operators in the process
o To pay attention:
 In case of just a machine workcenter, all the manual operations for finishing the
parts should be incorporated in that labor time
 The waiting times before restarting the cycle are not to be included in the
calculation. They are part of the efficiency of the process or they are absorbed
by the number of operators
o Number of individual capacities: 1 (each machine will be one)
 Waterjets, welding machines:
o Base quantity: the number of identical parts (identical cavities) by the number of tables
available in the waterjet (not the number of available tools)
o Machine time: corresponding to the cycle time
 For a simple table process:
 Start cycle bottom (or signal)
  Table entrance
 Cutting / welding time
 Table exit
 Unloading parts
 Loading semi-finish
 For a double table process (if there is no second tool, the time should be
calculated):
 Start cycle bottom (or signal)
 Table rotation
 Cutting / welding time, if unloading and loading in hidden time. If
unloading and loading is longer, the unloading and loading time
 Table rotation
 Cutting time (idem)
o Labor time: the cycle time machine by the number of operators in the waterjet
o The waiting times before restarting the cycle are not to be included in the calculation.
They are part of the efficiency of the process or they are absorbed by the number of
operators
o Number of individual capacities: The number of tables
 Simple foaming fix positions:
o Base quantity: the number of identical parts (identical cavities) by injection
o Machine time: corresponding to:
 Start cycle bottom (or signal)
 Foaming process
 Close tool time
 Opening time
 Unloading tool
 Open tool activities (cleaning, releasing, dressing the tool)
o Labor time: the machine time by the number of operators in the process
o Number of individual capacities: 1 (one position)
 Carrousels / Stadiums / Multiple foaming positions:
o To make the difference if there is manual finishing operation or just foaming process
o If just foaming process:
 Base quantity: the number of identical parts (identical cavities) by the number of
available positions (independently of the number of available tools). We need to
imagine that the line is 100% full of the same tools
 Machine time: the time to complete a rotation of the carrousel table, from
position 1, to position 1
 Labor time: the machine time by the number of operators linked with the
process
 If there are finishing operations, they should be absorbed by the number
of operators, or by the efficiency
 o If finishing operations out of the foaming, there should be two different workcenters
 For machine workcenter:
 Base quantity: the number of identical parts (identical cavities) by the
number of available positions (independently of the number of available
tools)
 Machine time: the time to complete a rotation of the carrousel table
 Labor time: the machine time by the number of operators in the
carrousel
 For finishing operations workcenter:
 Base quantity: part by part
 Labor time: the real time to finish the part by one operator
 Machine time: the labor time divided by the number of operators
working in parallel
o Number of individual capacities: the number of positions
 Sewing process:
o Base quantity: lot by lot
o Labor time: the real time to make the batch by one operator
o Machine time: the labor time
o Number of individual capacities: the number of identical machines in the sewing cell
 Finishing process:
o All finishing, rework process with no specific machine or just manual tools
o Bases quantity: part by part
o Labor time: the real time into the operation done by one operator
o Machine time: the labor time divided by the number of operators working in parallel
o Number of individual capacities: the maximum number of operators that can work in
parallel way
 Rework process:
o By definition, the rework is never in the routings. It’s taking in count in the efficiency of
the process / step that creates the rework
 Chemical preparation:
o Base quantity: the economical batch
o Machine time: the time for preparation: adding components (manual or automatically) +
mixing components + transfer time to storage
o Labor time: the machine time
o Number of individual capacities: the number of available reactors
Phantom semi-finished articles
 When we consider phantom articles, we need to generate two different routings to include the
phantom production:
o The SF routing following the operations for the phantom production
o The FG (that contents the phantom part number) routing, incorporating all the
operations for the phantom production as first operations of the routing
 This routing and its production version will allow to declare the assembly scrap