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    Solution To Operations Management W9

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    Đỗ Nguyễn Anh Thư
    This document contains solutions to operations management problems involving kanban systems, production planning, and takt time calculation. The first problem determines the number of containers needed for a kanban system based on usage rate, inefficiency factor, and container capacity. The second problem schedules production quantities for different products across multiple cycles to achieve level production. The third problem calculates takt time given total shift time, breaks/lunch, and daily demand.

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    Solution To Operations Management W9

    Uploaded by

    Đỗ Nguyễn Anh Thư
    374 views3 pages
    This document contains solutions to operations management problems involving kanban systems, production planning, and takt time calculation. The first problem determines the number of containers needed for a kanban system based on usage rate, inefficiency factor, and container capacity. The second problem schedules production quantities for different products across multiple cycles to achieve level production. The third problem calculates takt time given total shift time, breaks/lunch, and daily demand.

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    Solution to Operations Management W9

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    This document contains solutions to operations management problems involving kanban systems, production planning, and takt time calculation. The first problem determines the number of containers needed for a kanban system based on usage rate, inefficiency factor, and container capacity. The second problem schedules production quantities for different products across multiple cycles to achieve level production. The third problem calculates takt time given total shift time, breaks/lunch, and daily demand.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    374 views3 pages

    Solution To Operations Management W9

    Uploaded by

    Đỗ Nguyễn Anh Thư
    This document contains solutions to operations management problems involving kanban systems, production planning, and takt time calculation. The first problem determines the number of containers needed for a kanban system based on usage rate, inefficiency factor, and container capacity. The second problem schedules production quantities for different products across multiple cycles to achieve level production. The third problem calculates takt time given total shift time, breaks/lunch, and daily demand.

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    The document discusses operations management concepts like kanban systems, production planning, takt time calculation, and level production.

    3 containers should be used for the kanban system described. As the system improves, fewer containers will be needed due to decreased cycle time and inefficiency.

    The production plan is: Cycle 1: A(7), B(4), C(1), D(5). Cycle 2: A(7), B(4), C(1), D(5). Cycle 3: A(7), B(4), C(1), D(5).

    Operations Management – OMGT2199

    Week 9

    1. To

    2. A manager wants to determine the number of containers to use for incoming parts for a kanban
    system to be installed next month. The process will have a usage rate of 80 pieces per hour. Because
    the process is new, the manager has assigned an inefficiency factor of .35. Each container holds 45
    pieces, and it takes an average of 75 minutes to complete a cycle. How many containers should be
    used? As the system improves, will more or fewer containers be required? Why?

    Solution
    D = 80 pieces per hour
    C = 45 pieces per container
    T = 75 minutes
    X = .35

    Determine the number of containers:


    Convert T to hours so that both D and T use the same units:
    T = 75/60 = 1.25 hours

    DT ( 1+ X ) 80 ( 1.25 ) (1+.35)
    N= = =3
    C 45
    As the system improves, the number of containers will decrease due a decrease in the average time
    to complete a cycle and a decrease in the inefficiency factor.

    3. Determine the number of cycles per day and the production quantity per cycle for this set of
    vehicles:
    Daily
    Product Quantity
    A 21
    B 12
    C 3
    D 15

    Solution
    Given:
    Daily
    Product Quantity
    A 21
    B 12
    C 3
    D 15
    Use the sequence A-B-C-D.

    [Type text] Page 1


    Solution
    Determine the number of cycles per day and the production quantity per cycle:

    Step 1:
    Determine the smallest integer that can be divided evenly into each model’s daily quantity.
    Each value is divisible evenly by 3. There will be 3 cycles per day.

    Step 2:
    Determine the production plan:

    Daily Units per


    Product Quantity Cycle
    A 21 21/3 = 7
    B 12 12/3 = 4
    C 3 3/3 = 1
    D 15 15/3 = 5

    Pattern each cycle:


    A(7), B(4), C(1), D(5).

    4. Determine the number of cycles per day and a production quantity per cycle for this set of products
    that achieves fairly level production:
    Daily
    Product Quantity
    F 9
    G 8
    H 5
    K 6

    Assume the production sequence will be F-G-H-K.

    Solution
    Processing order = F-G-H-K.
    Daily
    Product Quantity
    F 9
    G 8
    H 5
    K 6

    The smallest daily quantity is 5. However, none of the other daily quantities are divisible by 5. Using
    5 cycles and producing 1 unit of each product per cycle would leave some products, as shown in the
    following table. Hence, if 5 cycles are used, some extra units will have to be made in some cycles.
    Daily Units per
    Product quantity Cycle
    F 9 9/5 = 1.8
    G 8 8/5 = 1.6
    H 5 5/5 = 1
    K 6 6/5 = 1.2
    [Type text] Page 2
    One possibility would be:
    Cycle 1 2 3 4 5
    Pattern F(2)–G–H–K(2) F(2)-G(2)-H-K F(2)-G(2)-H-K F(2)-G-H-K F-G(2)-H-K
    Extra units(s) F, K F, G F, G F G

    5. Compute the takt time for a system where the total time per shift is 480 minutes, there is one shift,
    and workers are given two 15-minute breaks and 45 minutes for lunch. Daily demand is 300 units.
    Solution:
    Total time per shift = 480 minutes.
    There is 1 shift and workers are given two 15-minute breaks and 45 minutes for lunch.
    Daily demand is 300 units.

    Step 1:
    Compute net time available per shift.

    Net available time = 480 – (15 + 15 + 45) = 405 minutes/shift.

    Step 2:
    Compute the net time available per day.

    405 minutes/shift x 1 shift/day = 405 minutes/day.

    Step 3:
    Compute the takt time.

    Net time available per day 405 minutes /day


    Takt time= = =1.35 minutes/unit
    Daily demand 300units /day

    [Type text] Page 3

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