production

1. PATTERN
PRODUCTION
- SPE Team

2. Definition:
Pattern production is a fixed schedule
production where set of parts are
arranged in a sequence.
Basic Principles:
i) Fixed time variable quantity
ii) Fixed quantity variable time
Basic Principles:
i) Fixed time variable quantity
ii) Fixed quantity variable time

3. Fixed time variable quantity
09.00
10.00
10.00
11.00
11.00
12.00
12.00
13.00
13.00
14.00
Fixed
Time
Variable
quantity A -90
Fixed quantity variable time
Fixed
quantity
Variable
time
09.00
10.00
10.00
11.00
11.00
12.00
(Kanban A = 90)
A -100
In this case, wait till the
Kanban qty (A) comes
to 100
In this case, regardless of
qty start at 9.00 am

4. WHY Pattern Production?
1. Capacity without change over is ok
- Pattern Production not required

5. 1. Capacity without change over is ok
- Pattern Production not required
- Our total load time is less than the shift time

6. WHY Pattern Production?
1. Capacity without change over is ok
- Pattern Production not required
2. Capacity with change over is ok
- Pattern Production not mandatory

7. 2. Capacity with change over is ok
- Pattern Production not mandatory
- Our total load time (With changeover) is less than the shift time

8. WHY Pattern Production?
1. Capacity without change over is ok
- Pattern Production not required
2. Capacity with change over is ok
- Pattern Production not mandatory
3. Capacity without change over is not ok
- Capacity constraint cannot meet the customer demand

9. 3. Capacity without change over is not ok
- Capacity constraint cannot meet the customer demand
- Our total load time is greater than the shift time (Capacity
constraint)

10. WHY Pattern Production?
1. Capacity without change over is ok
- Pattern Production not required
2. Capacity with change over is ok
- Pattern Production not mandatory
3. Capacity without change over is not ok
- Capacity constraint cannot meet the customer demand
4. Capacity without change over is ok and capacity with changeover is not ok
- Pattern production is mandatory

11. 4. Capacity without change over is ok and capacity with changeover is not ok
- Pattern production is mandatory
Capacity without
changeover is ok
Capacity with
changeover not ok
We should
go for
pattern

12. Data required for preparing the Pattern production
1. Number of machines
2. Production capacity (SPM)
3. Volume required per day
4. Dandori time and material loading time (Minutes)
5. Total Avl. working time in a day (minutes)
6. Total Part numbers (Models / Variants)

13. Pattern production
Example:
Capacity without Changeover is ok Capacity with Changeover is not ok
Lot size calculation:
=Requirement per shift X number of patterns

14. Lot size calculation:
=Requirement per shift X number of patterns
Example:
Going for 01 pattern, SPM is 6 then
A = 300 X 1 =300/6 = 50min (Load time = 50 +30 (dandori))
Going for 02 pattern, SPM is 6
A = 300 X 2 = 600/6 = 100min (Load time = 100 + 30 (dandori))
Similarly do this calculation for all parts and check on which pattern
the load time is less than the shift time.

15. .
.
.
E & F
parts Not
able to
complete
Trail 1
Trail 3
Able to
satisfy
customer
requirement
Pattern production
Stop time
(can be used for kaizen
and human devp.)

16. Deciding the store stock for the above example
For 03 pattern how much stock should we keep.
Store Stock:
= Lot size (Req. per shift x no. of patterns) + Safety stock(01 shift qty)
A = (300*3)+300=1200
Min Max for part number A
Max = 1200 and Min = 300

17. Benefits of Pattern production
 Effective utilization of all resources.
 Elimination of daily production planning.
 Unplanned O.T is eliminated.
 Variation in production in minimized (helps in
maintaining stock)