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Based on the given data answer the following questions:
i. What is the Takt time?
ii. Calculate the actual cycle times for each operation.
iii. Calculate the production lead time.
The manager at FunQ, nc collected the value stream mapping data from one of the company’s manufacturing cell. This cell produces a special steel part that is widely used in automotive industries. The data is shown in the below table. Average demand 180 units/day Batch size: 30 units Number of shifts per day: 1 Basic cel nformation Availability: 8-hours shift with including two 30 min breaks (60 min break time in total), 7 hours net available time Cycle time-140 sec Setup time 0 min operation 1 Cutting Uptime 9096 operator 1 WIP. 900 units Cycle time-150 sec setup time 40 min for every standard batch operation 2 Bending Uptime 100% operator 1 WIP-1000 units Cycle time-130 sec Setup time 0 min operation 3 Moulding Up time-9096 Operator 1 WIP-1500 units
Expert Answer
ii.
Actual cycle time for Cutting operation = Cycle time / Uptime = (140 + 0) / 90% = 155.6 sec
Actual cycle time for Bending operation = (150 + 40*60/30) / 100% = 230 sec
Actual cycle time for Moulding operation = (130 + 0) / 90% = 144.4 sec
iii. Bottleneck operation is Bending. Throughput of the whole system is equal to the throughput of the bottleneck operation. Therefore, throughput = 3600/230 = 15.65 per hour.
Production lead time = lead time of cutting operation + leadtime of bending operation + leadtime of moulding operation
leadtime of each operation = WIP / throughput
Production lead time = lead time of cutting operation + leadtime of bending operation + leadtime of moulding operation
= 900/15.65 + 1000/15.65 + 1500/15.65 = 217
