A) Suppose a lean work center is being operated with a container size of 40 unit

Question

A) Suppose a lean work center is being operated with a container size of 40 units and a demand rate of 200 units per hour. Also, assume it takes 2 hours for a container to circulate. 1. How many containers are required to operate this system? 2. What is the maximum inventory that can accumulate? 3. How many Kanban cards are needed? B)For a particular operation, the setup time is 5 minutes and the run time is 40 minutes to produce a standard lot of 80 parts. It takes four additional hours to circulate a container of parts after production is completed. The demand rate is 16,000 parts per

Explanation / Answer

Answer to question # A :

Cycle time of the process = 2 hours

Demand rate = 200 units / hour

Therefore, total in process inventory = 200 x 2 = 400 units

Container size = 40 units

Answer to question # B :

Total processing time of a lot

= set up time + run time + circulation time

= 5 minutes + 40 minutes + 4 hours

= 45 minutes + 4 hours

= 0.75 hours + 4 hours

= 4.75 hours

Monthly demand rate = Monthly production requirement in parts / parts per lot = 16000/80 = 200 lots

Available production hours in a month = 160

Therefore , hourly production rate = 200 /160 = 1.25 lots per hour

Therefore, total in process inventory

= Hourly production rate x Total processing time of a lot ( hours)

= 1.25 x 4.75

= 5.93 lots or containers ( 6 containers rounded to next higher whole number )

Takt time of the process

= 1.25 lots per hour

= 80 x 1.25 parts per hour

= 100 parts per hour

Number of standard containers needed = 6 numbers

Takt time of the process = 100 parts per hour

Number of standard containers needed = 6 numbers

Takt time of the process = 100 parts per hour

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