MSD Training: Cycle Time Machine & Operator Balance & Utilization

Types of Manual Work

Repeatable / Predictable Non-Repeatable / Unpredictable

Continuous Flow Small Lot Flow

Cyclic Long Cycle

Non-Cyclic

Cyclic Work is typically quantified in seconds per piece while Non Cyclic Work & Long Cycle is typically quantified in minutes per work element. Examples:
Cyclic Work Final Assembly Operator @ 15 sec/pc Long Cycle Work Tugger Driver @ 20 min route Non-Cyclic Work Machine Repairman responding to Andon board

Convert Non-Cyclic Work to Long Cycle Work as much as possible. Avoid mixing Cyclic, Long Cycle, Non Cyclic, types of work in one job.

Machine and Operator Utilization

Before completing a Balance and Utilization chart, you must first be familiar with the terms that are used to describe the different components of machine and operator cycle times.
wait load

Forced Wait Operator Cycle Time Walk Non-Value Added Manual Work Value Added Manual Work

Manual Work While the Machine Waits Machine or Process Cycle Time CT ET Value Added Machine Element Time

machine unload machine

designed into work sequence

walk reach twist bend hold load,

Machine Element Time

Non-Value Added Machine Element Time

index transfer wait press drill test weld

CT

Total Manual Work ET

unload assemble install inspect

Seconds

3 Machines

3 Operators

2. Machine Data Input

For each machine in the process enter:

a. b. c. d. e. f. Operation Number Machine Name Number of Pieces per Cycle Machine Element Time (optional) Value Added Machine Element Time Manual Work While the Machine Waits

As data is entered for each machine, the Machine or Process Cycle Time, Number Shifts for Manufacturing Plan, Design Cycle Time (ATT) and Takt Time columns will automatically fill.

You will now scroll down to enter the operator cycle time data.

3. Cyclic Operator Data Input

For each cyclic operator in the process enter:

a. b. c. d. e. f. g. Operator ID Work Description Number of Pieces per Cycle Manual Work Time (optional) Value Added Manual Work Time (optional) Forced Wait Time Inside the Manual Work Cycle Walk Time
Note: By default this data column is collapsed, if you need to enter forced wait, you must click on the + sign above column H.

As data is entered for each operator, the Operator Cycle Time, Number Shifts for Manufacturing Plan, Design Cycle Time (ATT) and Takt Time columns will automatically fill.

You will now scroll down, past the machine and operator utilization charts, to enter the non-cyclic operator cycle time data.

d e

4. Non-Cyclic Operator Data Input

For each non-cyclic operator in the process enter:

a. b. c. d. Operator ID Work Description Total Manual Work Time Walk Time

As data is entered for each operator, the Operator Cycle Time, Number Shifts for Manufacturing Plan, Design Cycle Time (ATT) and Takt Time columns will automatically fill. Non-cyclic operator data is plotted as minutes per shift.

Utilization Charts