Glass-cutting Process Analysis
Case 1: Two people work on CNC glass cutting machine

1. The process segments before used Free Fall System (See the Chart)

During one cycle time of glass-cutting:

A. Operator I on the third table (break table), he divides the glass pieces after cutting and put them into the cart.
Time cost:
84 seconds on average
B. Operator II on the first table ( free fall table ): Put one glass down from the rack and push it to the second table ( cutting table).
       Time cost:
21seconds on average
C. Glass cutting machine aligns and cuts glass
Time cost:
45 seconds on average

Because the process segments A , B and C can be parallel, the cycle time of glass-cutting is longest process segment which is process segment A.
The time consumed in process A: 84 seconds and use two operators.

The cycle time:
84 seconds.

Analysis:  As data showing above, the good way to decrease unit time to increase the productivity is to speed up the process segment A.

2. The process after used Free Fall System (See the Chart)
A. Operator I and II on the third table (break table), they both divides the glass pieces after glass cutting and put them into the cart.
Time cost: 42 seconds on average
B. FreeFall system pull glass down from the glass rack and push it to the second table
       Time cost: 21seconds on average
C. CNC machine aligns and cuts glass
Time cost: 45 seconds on average

The cycle time:
45 seconds.

By using FreeFall system to load the glass to cutting table, one operator is free and can assign him to divide glass on break table. The productivity can be nearly double as before.

  Productivity increase rate = 84 seconds / unit  / 45 seconds /unit   = 1.87

By using FreeFall system to load glass, either can save two labors on 2 shift/day or the productivity can be increased to 1.87.

Return on Investment By Using One Free-Fall System

As previous analyzed, by using Free-Fall Loading System in glass cutting process, it can either saves two labor in two shifts/day or increase 87% of productivity in glass cutting process.

(1) Existing Labor Saving

Save two labors in two shifts/day

    2 labor x 2080 hrs/shift x $8.00/hr + 30% benefits cost =
$ 43,264 Annual Labor Cost

(2) Increase Annual Revenue Stream

Increase 87% of Glass-cutting CNC Machine

    87% productivity x 90% green light time x  2080 hrs/shift x 2 shift x $200/hr billable revenue =
$ 651,456 Billable revenue/year.
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