250,000 units/yc Customer Demand Typical Production 3. 20 days/month 1 shift 8 b

Question

250,000 units/yc Customer Demand Typical Production 3. 20 days/month 1 shift 8 brs/day 480 min/shift Determine a Daily Demand b Hourly Demand C TAKT time (sec/unit) sec/unit Determine TAKT for each letter using only designated constraints as inputs d Breaks e Breaks f Scrap rate @ g Scrap rate @ h Rework @ i Equipment Uptime j Daily Meetings k Breaks 30 min/shift 20 min/shift 100 pcs/day 10% 5% 90% 5 min/shift 30 min/shift 5 min/shift 50 pcs/day 20 min/shift 10% 95 % Daily Meeting Scrap l Breaks Rework Uptime

Explanation / Answer

3.a) Customer demand=250,000 units/yr

Daily demand=250,000/365=684.93 approximately

b) Hourly demand=684.93/24=28.54 approximately

c) Production time per day is 8 hrs or 480 minutes or (480*60)=28,800 seconds

Consumer demand per day is calculated as 684.93

TAKT time=28,800 secs/684.93=42 seconds

d) Now,the break time is 30 minutes/shift.

Thus,the total working time would be 450 minutes/shift or (450*60)=27,000 seconds

TAKT time=27,000 secs/684.93=39.42 seconds/unit

e) If the break time is 20 minutes/shift.

Hence,the total working time would be 460 minutes/shift or (460*60)=27,600 seconds

TAKT time=27,600 secs/684.93=40.3 seconds/unit

j) If the daily meetings are 5 minutes/shift

Hence,the total working time would be 475 minutes/shift or (475*60)=28,500 seconds

TAKT time=28,500 secs/684.93=41.61 seconds/unit

k) Now,breaks are 30 minutes/shift,daily meetings are 5 minutes/shift and scraps are 50 pcs/day.

The working time is 445 minutes/shift or (445*60)=26,700 seconds.If scraps are 50/day then the daily production becomes=(684.93-50)=634.93

TAKT time=26,700/634.93=42 seconds approximately

h) The rework is 5% or the total units to be reworked=(0.05*684.93)=34 pieces

Thus additional time to make the 34 pieces/units=48.51 minutes

Total working time becomes=(480+48.51)=528.51 minutes or (528.51*60)=

TAKT time=31,711/684.93=46.3 seconds

i) The equipment uptime is 90% and thus the total working time now becomes=(0.9*480)=432 minutes/shift or (432*60)=25,920 seconds

TAKT time=25,920/684.93=37.84 seconds

f) The scraps are 100 pieces/day.Hence,the daily production equals=(684.93-100)=584.93

The working time is 480 minutes/day or (480*60)=28,800 seconds

TAKT time=28,800/584.93=49 seconds approximately

l) The break time is 20 minutes/shift,rework is 10% and uptime is 95%.

Hence,total number of units to be reworked=(0.1*683.94)=68.39.Thus,total number of pieces/units to be made in a day=(684.93+68.39)=753 approximately

The breaktime is 20 minutes/shift.Thus,the total work time per shift=(480-20)=460 minutes or (460*60)=27,600 seconds

Now,the uptime is 95% or the final worktime per shift=(0.95*480)=456 minutes or (456*60)=27,360 seconds

Hence,TAKT time=27,360/753=36.33 seconds

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