Production throughput and material yield · Lesson 4 of 4

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.

9 min · 11 slides · 6 questions

All lessons in this module

Slide 1 of 11

Yield defects to look for

A width just past a breakpoint. Short pieces cut one per strip. Lengths that add up to exactly 10 ft with no cut allowance. Pieces remade after a miscut or misfold. Drops of mixed metals. Jobs piling up between stages.

Each has a different fix and a different owner.

Sources

AFS quote convention - Architectural Flashing Supply
AFS Material Takeoff, Nesting & Bill of Materials tool and its published method (method 1.2) - Architectural Flashing Supply
The Lean and Environment Toolkit (EPA-100-K-06-003, October 2007), chapter 2 - U.S. Environmental Protection Agency
Little's Law as Viewed on Its 50th Anniversary, J.D.C. Little, Operations Research 59(3):536-549, 2011 (reprinted with the permission of the author and INFORMS) - Project Production Institute (reprint)

Glossary

Planned versus actual: Comparing the sheets, utilization and first-pass yield a plan predicted with what the shop really pulled and made, and recording why they differ.
Remnant: A usable drop kept for a later job of the same metal and thickness. Under 29 CFR 1910.176(b) its storage must not create a hazard, and if stored in tiers it must be stacked, blocked, interlocked and limited in height so it is stable and secure.
Defect (lean waste): One of the seven deadly wastes EPA lists: making a defective part consumes raw materials and energy, which then need recycling or disposal.