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Production throughput and material yield · Lesson 1 of 4

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.

12 min · 12 slides · 9 questions

All lessons in this module
Slide 1 of 12

Two kinds of yield

Two measures: how fast work leaves the shop (throughput) and how much of each sheet ends up in finished pieces (material yield).

In AFS's takeoff method, utilization is the area of the finished pieces divided by the area of the sheets used.

ASSEMBLY magazine defines first-pass yield as usable parts divided by total parts built in a run.

A piece made twice uses metal twice.

Videos for this lesson

What this video shows: A short Gemba Academy explainer: what cycle time, takt time and lead time are and how to determine them (from the video's own description).

Video: How to Determine Cycle Time, Takt Time and Lead Time by Gemba Academy, on YouTube. AFS checked its description against this lesson.

What this video shows: A university lecture on the relationship between inventory, throughput rate and flow time: Little's Law (from the video's title and description).

Video: Process Analysis Little's Law (Video 9) by Prof. Bussom - Widener University, on YouTube. AFS checked its description against this lesson.

What this video shows: A consultancy explainer of Goldratt's five focusing steps: identify, exploit, subordinate, elevate, and do not let inertia become the constraint (from the video's own description).

Video: The 5 Focusing Steps of the Theory of Constraints by Marris Consulting, on YouTube. AFS checked its description against this lesson.

Glossary

Throughput
The average output of a production process (machine, workstation, line or plant) per unit time, as defined by Hopp and Spearman and quoted by J.D.C. Little (2011).
Work in process
The inventory between the start and end points of a product routing: the jobs started but not yet finished (Hopp and Spearman, quoted by J.D.C. Little, 2011).
Cycle time
The time required to produce a part or complete a process, as timed by actual measurement (Lean Lexicon).
Production lead time
Also called throughput time: the time a product takes to move all the way through a process or value stream from start to finish (Lean Lexicon).
Takt time
Available production time divided by customer demand. The Lean Lexicon example: 480 minutes a day and 240 units demanded gives a takt of 2 minutes.
Little's Law
L = λW: the average number of items in a system equals the average arrival rate times the average time each item spends in the system (J.D.C. Little, 2011).
Constraint
The resource whose output governs the output of the whole system; the Theory of Constraints Institute's five focusing steps start by identifying it.
Utilization (material)
In AFS's takeoff method, the area of the finished pieces divided by the area of the sheets used, as a percent.
Drop
The unused remainder of a sheet or strip: leftover width beside the strips, or leftover length after the pieces are cut.
First-pass yield
Usable parts divided by total parts built in a run, as defined in ASSEMBLY magazine: the quality side of yield.
Muda
Any activity that consumes resources without creating value for the customer (Lean Lexicon).