Course book: Factory Physics 3rd edition by Hopp Wallace.? You have just complet
ID: 452324 • Letter: C
Question
Course book: Factory Physics 3rd edition by Hopp Wallace.?
You have just completed a Value System Map of simple, single-shift, 5 station production line and have the following data that defines the Current-State Map: Customer demand is 7,200 units/month (assume 20 days/month for work days) Inventory counts between the stations are: 2,250; 2,600; 1,800; and 2,350 pcs. Available daily work time is 7 hours (breaks and lunch removed). You measured the average production throughput (TH) at 40 jph. Calculate (enter only the number in the first 4 boxes): Customer daily requirements (units per day). Total leadtime (in days) due to WIP inventory counts (Little's Law). Find the talk time required to meet the customer demand (in seconds per unit). Calculate the actual cycle time (convert 40 jph to seconds/unit) for comparison. Answer the question in the 5th box: Is the line producing too fast or too slow (enter: either fast or slow in the box provided).Explanation / Answer
1. ) Actual demand per day =7200/20 =360
2.).Total lead time in days = WIP/ACR where ACR= Average completion rate
=(2250+2600+1800+2350)= 9000
& Per hour job production rate = 40.er day = 40*7= 280
Thus lead time for 9000 units – 9000/280 = 32 days
3. ) Actual takt time = 7200/ ( 5*7*60)
=(35*60*20)/7200= 5.822 min, where 20= working days
4.) Cycle required to meet customer demand
Takt Time = Actual Production Time / Customer Demand
= (40*7)= planned production time = 280 hrs= 280*60= 16800
Customer demand = 7200
Cycle time = 16800/7200 = 2.33 min