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Throughput time variation reduction
On-time delivery of products (FR-112) is dependent on the
reduction of variation in throughput time. Throughput time
variation is largely a consequence of the degree of disruptions
in the manufacturing system as well as how these disruptions
are resolved. Disruptions as indicated by the MSDD are problems
that lead to a loss in system availability. Quality problems,
though disruptive to a manufacturing system, are treated separately
under the previously described FR-111 “Manufacture products
to target design specifications” branch and therefore
the decomposition of DP-112 (Throughput time variation reduction)
considers only disruptions that do not result from quality
problems. Figure 1 shows the first level of decomposition
of FR/DP-112.
Figure 1 Decomposition of throughput time variation reduction.
Decreasing the variation of delivery time to the customer
requires a manufacturing system to have predictable output.
With greater predictability, a company can make promises to
its customers with the confidence and assurance that it can
meet promised delivery times. When customers consistently
receive products in the same amount of time from one order
to the next, they are likely to gain confidence in the ability
of the manufacturer to satisfy their orders. The result is
a strengthened business relationship.
The requirement to produce with a predictable time output
reflects a manufacturing system’s ability to decrease
variation in delivery time. Producing in a consistent and
timely manner can be done when production resources are reliable
and in themselves predictable. The resources that affect timely
production are having sufficient material supply, adequate
machine availability, and consistent labor productivity. The
ability to resolve production disruptions (DP-R1) is a prerequisite
for minimizing production disruptions. Thus, the design matrix
for the decomposition expresses a partially coupled design
as shown in Figure 1.
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