Question

1. For a particular operation, the setup time is 10 minutes and the run time is 50 minutes to produce a standard lot of 40 parts. It takes three additional hours to circulate a container of parts after production is completed. The demand rate is 20,000 parts per month. There are 160 production hours in a month.

a. How many standard containers are needed? n = D(T) / C Use the following inputs: Demand rate (D) = ________ parts / hour Lead Time (L) = ________ hours Container size (C) = ________ parts

b. What is the takt time of this process?

2. A plant operates 2000 hours per year and the demand rate for parts is 100,000 per year. The circulation time for each kanban container is 24 hours. Given: Demand rate (D) = 100,000 units per year Lead time (L) = 24 hours / 2000 hours/per year = 0.012 of a year Container size (C) = 100 parts

a. How many kanban containers are needed for a container size of 100 parts?

b. What would be the effect of reducing the containers to 60 parts?

c. What is the takt time for 80,000 units per year?

Answer 1

its given:

D = 20000 parts/months

also, there are 160 production hours in a month

Hence, D = 20000/160 parts/hour = 125 parts/month

Lead time(T) = setup time+process time+move time = 10min + 50min+ 3 hours = 4 hours

Container size(C) = 40

Number of containers = D *T/C = 125*4/40 = 12.5 or 13(rounding off)

B) Takt time

It is production time available divided by the demand

In this case,

Production time in a month = 160 hours

Demand = 20000 parts per month

Hence, takt time = 160/20000 hours = 0.008 hours or 0.48 minutes