3
Figure B.4 Capacity Utilization: Tropical Blends Corpor CAPACITY BREAKDOWN HOURS 2,000 Standard runtime 900 Runtime losses 50 Equipment setup 150 Clean-up 300 Equipment breakdown 200 Rework 100 Preventive maintenance 80 Total hours used 1,780 220 6,640 Maximum time available 8,640 Available time based on manned Idle—unused 2 Idle—unavailable 3 1 Available time equals 250 workdays x 8 hour per day = 2,000 2 Idle unused = available time less total hours used = 2,000 - 1,780 3 Idle unavailable = maximum time less available time = (360 days x 24 hours) - 2,000 = 8,6

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Page 1: Appendix B.templates

Figure B.4 Capacity Utilization: Tropical Blends Corporation

CAPACITY BREAKDOWN HOURS 2,000

Standard runtime 900 Runtime losses 50

Equipment setup 150 Clean-up 300 Equipment breakdown 200 Rework 100 Preventive maintenance 80

Total hours used 1,780

220

6,640

Maximum time available 8,640

Available time based on manned shifts1

Idle—unused 2

Idle—unavailable3

1Available time equals 250 workdays x 8 hour per day = 2,0002Idle unused = available time less total hours used = 2,000 - 1,7803Idle unavailable = maximum time less available time = (360 days x 24 hours) - 2,000 = 8,640 - 2000 = 6,640

Page 2: Appendix B.templates

Figure B.5 CAM-I Reporting Model for Tropical Blends Corporation

CAPACITY UTILIZATIONEQUIPMENT LABOR

Hours % Utilization Costs* Hours % Utilization Costs

Idle

Off-limits 6,640 77% $ 527,450 - 0% $ - Marketable 220 3% 20,550 220 11% 33,000 Subtotal idle 6,860 80% 548,000 220 11% 33,000

Nonproductive Equipment setup 150 2% 13,700 150 8% 24,000 Clean-up 300 3% 20,550 300 15% 45,000 Downtime 200 2% 13,700 200 10% 30,000 Rework 100 1% 6,850 100 5% 15,000 Preventive maintenance 80 1% 6,850 80 4% 12,000 Run time losses 50 1% 6,850 50 3% 9,000 Subtotal nonproductive 880 10% 68,500 880 44% 132,000

Productive Run time (good products) 900 10% 68,500 900 45% 135,000 TOTAL 8,640 100% $ 685,000 2,000 100% $ 300,000

* Equals cost per activity x % total time

For example, idle off limits = $685,000 x 32% = $527,450

Page 3: Appendix B.templates

Figure B.6 Resource Effectiveness Model for Tropical Blends Corporation

EQUIPMENT LABOR

CAPACITY UTILIZATIONHours Cost Hours Cost

6,640 77.0% $ 527,450 - - $ - $ 527,450

Idle—off limits 220 3.0% 20,550 220 11.0% 33,000 53,550

Idle—unused 80 1.0% 6,850 80 4.0% 12,000 18,850

Planned downtime 200 2.0% 13,700 200 10.0% 30,000 43,700

Unplanned downtime 450 5.0% 34,250 450 22.5% 67,500 101,750

Ancillary time 150 2.0% 13,700 150 7.5% 22,500 36,200

Runtime losses 900 10.0% 68,500 900 45.0% 135,000 203,500

Standard runtime 8,640 100.0% $ 685,000 2,000 100.0% $ 300,000 $ 985,000 Maximum time

Percent Formula

$ 217,850 52.5% (runtime ÷ available time)

Efficiency index $ 36,200 85.7% (standard runtime ÷ total runtime)

$ 254,050 45.0% (standard runtime ÷ available time)

Available time = runtime + ancillary time + downtime (planned and unplanned) + idle (unused) = 1,050 + 450 + 200 + 80 + 220 = 2,000

TOTAL COST% Total

Time% Total

Time

Cost Opportunity

Utilization index1

Effective utilization index2

Note: Runtime = Standard runtime + runtime losses = 900 + 150 = 1,050 hours

1 Cost opportunity utilization index = $53,550 + $18,850 + $43,700 + $101,750 = $217,8502 Cost opportunity effective utilization index = $53,550 + $18,850 + $43,700 + $101,750 + 36,200 = $254,050

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