Setting rate guidelines for new Paint System. 2

[ssummers]

My company has installed a new paint system in its new manufacturing facility. We had an old system which no longer is in use. I am reviewing the rates and they are outdated. My Question is what kind of allowances are typically used for this type of process. The line is 8 feet per minutes so it is easy to see how many pieces per hour we can paint. Our assemlby has been using a 15% PFD to account for personal time, Fatigue, and unexpected delay. My initial thoughts were to forget the personal time and take 90% of the maximum they can hang. If any one else has some experience with this, I would appreciate your comments. Thanks!

 

[BML]

Based on my involvment with lean manufacturing in the past, I would suggest you target 85% efficiency. If the line achieves higher than that, then either the standard is incorrect, or something is being done incorrectly (i.e. PM is not being performed).

Also, the number of variations of parts and colors will significantly impact your capacity, and thus productivity. Painting only one part in one color is the most efficient use of the paint line, but most of the paint lines I've seen have been high part mix (i.e. widely varying rack densities) and painted around 15 different colors per day. In those cases, they were doing well to get up to 60% or 65% productivity.

Hope this helps!

BML