Slide 1What is Process Flow?Systems for Managing FlowSystems for Managing Flow Drum-Buffer-Rope (DBR)Analysis of a bread-making operationAnalysis of a bread-making operationAnalysis of a bread-making operation1BA 341 – Lean OperationsDr. Bogdan BichescuImplications of TOC forProcess FlowWhat is Process Flow? Refers to the logical sequence of steps needed to make products or deliver services to customers It may include the passing of information or materials from one step to the next 2Distribution Underwriting Rating Policy WritingAgent20 policies/day 15 policies/day 7 policies/day 9 policies/day 15 policies/daySystems for Managing FlowMake-to-Stock (Push) - output is pushed to the next station as it is completed (based on Demand Forecast)Make-to-Order (Pull) - a workstation pulls output from the preceding station as needed (based on Demand)Systems for Managing FlowDrum-Buffer-Rope (DBR)TOC’s approach to controlling flowDrum – represents the system bottleneck Buffer – a protection for the drum, measured in time – all resources that feed the bottleneck must be given enough time to overcome any delays Rope – release materials only when neededPrevents early release of materialsPrevents accumulation of WIPFG A B C D E 7 9 5 8 6RMDrum (bottleneck)RopeTime BufferAnalysis of a bread-making operationWhat is the constraint process?What is the maximum system output?Raw MaterialBread MakingProcess Time:3/4 hr/100 loavesWIPPackCapacity:100 loaves/hrFinished GoodsAnalysis of a bread-making operationAssume that Bread Making works at full capacity for 8 hours. What are the consequences?Raw MaterialBread MakingProcess Time:3/4 hr/100 loavesWIPPackCapacity:100 loaves/hrFinished GoodsAnalysis of a bread-making operationHow many hours a day would you schedule for each process? Why?What are the resulting resource utilizations?Raw MaterialBread MakingProcess Time:3/4 hr/100 loavesWIPPackCapacity:100 loaves/hrFinished
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