Solutions in Action: With Rockwell Automation

Maximizing productivity is an objective all manufacturing facilities share. But on any integrated system, throughput is always constrained by the slowest machine on the line. “In other words, a typical manufacturing line is only as fast as its slowest machine,” said Tom Garvey, president, Garvey Corporation. “Our objective is to keep that constraint running at […]

Maximizing Thruput: Buffers!

The reason we put buffers into a system is to protect the constraint from the malfunctions of other machines. The last thing we want to do is to add downtime to the system caused by the buffers. That would defeat their whole purpose and render them useless. Buffers should be extremely simple in design principle. […]

Maximizing Thruput: Protect It

After the constraint has been chosen, or identified, the next step is to protect it. But, protect it from what? What you must protect the constraint from is the effect of malfunctions on machines that are non-constraints. You see, in a close-coupled system, anytime a non-constraint shuts down it immediately shuts down the constraint. This […]

Maximizing Thruput: Finding the Constraint in the Data

Finding the constraint is simple once the preliminary data previously discussed has been analyzed. You simply look for that operation which has the lowest net output. That net output is now going to be the lines potential thruput. 100% thruput will be whatever the constraint’s net output is. At this point, we have developed a […]

Maximizing Thruput: Example Calculations

Until now, we have been discussing the background on thruput and what you need to know to find it. Let’s take a look at a couple real world examples: Here is an example of how to calculate the POR or Probability of Run. If you think about the logic of the formula you will see […]

Maximizing Thruput: What You Need to Know

  It is really simple. If you know: The maximum RATE of the machine The average length of time a machine is down (MTR) How many times per hour or shift it goes down (MTBF) You have everything you need! Remember, it does not need to be exact. There are checks built into the system […]

Maximizing Thruput: Find It (Existing Line)

The analysis of the line is a fairly simple process, which will do the following: Identify the constraint Identify strategic buffer locations Identify the optimum capacity for the buffers Verify that there is sufficient rate capacity of the non-constraints Predict the effect on overall thruput Determine efficiency thresholds for each machine The collection of the […]

Maximizing Thruput: What’s the Point?

Welcome to our Maximizing Thruput series! When I was given an old folder full of slides and presentation notes from Mark Garvey written back in 2001, I thought I might be able to find some good content that would still be relevant. It didn’t take long for me to realize that it was ALL still relevant, […]

Packaging World Highlights Garvey Partnership With Parsec

The partnership between Garvey Corporation and Parsec was highlighted by PackWorld last week in an article titled “Portable tool good at pinpointing packaging line constraints.” The article focuses on how and why Garvey utilizes Parsec’s data analytics expertise to find the constraint in our customer’s production lines. This, of course, is the most crucial step […]