Work Combination Example

Work Combination Example

Problem Statement

Create a time-study and work combination study for the data given below. The TAKT Time for this exercise is 52 sec.

Process step

Time 1

Time 2

Time 3

Notes

Get part from the tub

8

7

10

NVA

Load part onto the fixture

20

15

17

 

Get tape from dispenser

3

2

 

NVA

Put tape on the assembly

5

7

9

 

Check alignment

2

 

1

NVA

Hit button to move transfer line

1

1

1

 

How to perform Analysis

Step 1: Open Sigma Magic
  1. Click on the Sigma Magic button on the Excel toolbar.
  2. Click on the New button to create a new project.
Step 2: Add analysis template
  1. Click on the Tool Wizard to add the analysis template.
  2. Click on Lean and then Work Combination.


Step 3: Specify analysis options
A new worksheet will be added to your workbook. Analysis Setup will be automatically opened, in the setup tab specify the following details.



Click on the Create button to save all changes and compute the outputs for this analysis. Review the results of your analysis by entering the details and make changes to your inputs if required to update analysis results. A sample screenshot of the worksheet is shown below.





If you need to make changes to the charts, click on the Analysis Setup and then the Charts tab. You can specify the following details,

 Labels:

  • Add a title for the chart.
  • Label the X-axis and Y-axis appropriately.

Appearance:

  • Adjust colors, font sizes, or other visual elements as needed.
  • Enable/disable gridlines or background shading.



Finally, click on Verify tab to ensure all the inputs are okay and shown in a green checkmark.




Step 4: Generate analysis results
Click Analyze button to update analysis results.



Interpreting Results

  1. The total cycle time is 38 minutes. This refers to the amount of time required to complete all process steps from start to finish.
  2. The VA percentage is 44.74%. This indicates that only 44.74% of the total cycle time is spent on tasks that add value to the final product or service. The rest of the time is spent on NVA activities.
  3. The Cycle Time is greater than the Takt Time, which is a definitive sign that the process in use cannot meet customer demand within the time frame desired.
  4. Steps such as "Get part from the tub," "Get tape from dispenser," and "Check alignment" are NVA activities and make up a lot of the delays.
  5. Removing or eliminating these activities could help streamline the process more.
  6. The highest duration of the process step "Load part onto the fixture" is 17 minutes, and hence it is a bottleneck in the workflow. This needs optimization for reduction in time.
  7. The delays in the process are not clearly mentioned, but the high cycle time shows that there are inefficiencies to be addressed.

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