Architectural Flashing Supply
Start a Quote
Tier 4 · Advanced Fabrication and Manufacturing

Production throughput and material yield

The words for how fast work leaves a shop and how much of each sheet ends up in finished pieces, how AFS's sheet and limits decide strips per sheet, a worked takeoff and throughput method, and how to find, fix and record yield and lead-time defects.

4 lessons · about 40 min · 8 diagrams · 5 videos

Version 1.0.0

Builds on these modules

Related Academy lessons

Lessons

0 of 4 complete

  1. Lesson 1 · 12 min · 12 slides · 9 questions

    Production throughput and material yield: principles and terminology

    The words a shop uses for how fast work leaves it and how much of each sheet ends up in finished pieces, and the machine-guarding and lockout rules that no schedule overrides.

    You will be able to: Define throughput, cycle time, lead time, takt, work in process, the constraint, utilization, drop and first-pass yield, state Little's Law with units, and state the safety rules that speed never overrides.

    Not startedStart →

  2. Lesson 2 · 9 min · 8 slides · 7 questions

    Production throughput and material yield: materials, standards and design constraints

    How AFS's 10 ft x 4 ft sheet, the blank width and the length limits decide how many strips a sheet gives, why a width just past a breakpoint wastes a whole strip, and what the sheet weighs.

    You will be able to: Work out strips per sheet from a blank width, spot a width just past a breakpoint, apply AFS's girth and length limits and stock convention, and say what the sheet standards do and do not cover.

    Not startedStart →

  3. Lesson 3 · 10 min · 11 slides · 7 questions

    Production throughput and material yield: methods and worked application

    AFS's takeoff method step by step, first fit decreasing in plain words, a worked job with and without a cut allowance, and worked throughput examples for lead time and the constraint.

    You will be able to: Run AFS's takeoff method by hand on a small job, show the effect of a cut allowance, estimate lead time with Little's Law and find the constraint, recording every assumption and unit.

    Not startedStart →

  4. Lesson 4 · 9 min · 11 slides · 6 questions

    Production throughput and material yield: defects, verification and case study

    The common ways a shop loses metal or time, how to check a plan against what the shop really pulled, a worked case on a wide profile, and the evidence packet a reviewer needs.

    You will be able to: Diagnose a yield or throughput defect from evidence, compare planned with actual sheets, utilization and first-pass yield, explain corrective options and who decides them, and assemble the evidence for review.

    Not startedStart →

Practical task

Plan and verify a small order of 24 ga galvanized flashing: three lines you choose from FlashDraft profiles without hems, at least one shorter than 120 in and none longer than 126 in. Work out strips and sheets, check every width for the width cliff, estimate lead time from given shop numbers, and write up one defect.

Hand in

  • The line list: profile, blank width, piece length and quantity, each with units and where the width came from
  • Strips per 48 in sheet for each width, with the nearest breakpoint (48 / k) and the drop beside the strips
  • A takeoff, by hand or with the Design Center material takeoff, with the cut allowance stated, the strip and sheet counts and the utilization
  • A marked-up layout sketch of the strips on each sheet, drops shown
  • A lead-time estimate by Little's Law from a stated work in process and finishing rate, with units
  • One defect analysis (for example short pieces one per strip, or a width just past a breakpoint): the evidence, the fix, who decides it, and what you will check after the run

Rubric

CriterionMeets the standard when
Strips per sheetEach width gives floor(48 / width) strips, the drop is right, and any width just past a breakpoint is flagged.
TakeoffPieces are pooled by material, thickness and width; the strip and sheet counts and the utilization match the method, and the cut allowance is stated.
LimitsNo blank is wider than 48 in, no piece is longer than 126 in, and pieces over 10 ft are listed as coil pieces.
ThroughputThe lead time is work in process divided by throughput, with units, and the constraint is named from the rates given.
EvidenceThe defect write-up states what was seen, the fix and its owner, and the planned-versus-actual checks; no prices appear anywhere.

Module quiz

10 questions drawn from a bank of 29; a new set each attempt. Pass mark 80%.

1. What share of the 48 in width does a 24.125 in blank use?
2. According to the Theory of Constraints Institute, what governs the output of the organization as a whole?
3. Where does first fit decreasing put each item?
4. Under 29 CFR 1910.147, which of these is servicing?
5. What does AFS's takeoff call its sheet count?
6. Planned two to a strip, how many sheets do 40 drip edge pieces at 42 in need?
7. What share of the 48 in width does one 24.75 in coping underplate strip use?
8. A value-stream map diagrams every step in which two flows?
9. First-pass yield is usable parts divided by what?
10. Why does AFS's quote count a whole strip for every piece shorter than 10 ft?