Operations Management
13th Edition
ISBN: 9781259667473
Author: William J Stevenson
Publisher: McGraw-Hill Education
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Chapter 14, Problem 1P
Summary Introduction
To determine: The number of containers used and will the system improve with requiring less or more containers.
Introduction: Kanban is a
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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 88 pieces per hour. Because the process is new, the manager has assigned an inefficiency factor of .23. Each container holds 58 pieces and it takes an average of 70 minutes to complete a cycle. How many containers should be used? (Round up your answer to the next whole number.) Number of containers As the system improves, will more or fewer containers be required? multiple choice
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A company is using a Kanban system with 2 containers, each holding 50 parts, between a downstream (using) and an upstream (producing) work center. The using work center can handle 250 jobs per day. The average elapsed time for the entire cycle is currently .25 days. The company is concerned with the safety factor for the operation and the size of the containers.
A: What is the efficiency rating of the current operation?
B: If the company decides to use only one container, how many parts must it hold?
C: If the safety factor is changed to .12 and there are still 2 containers, how many parts must each container now hold?
Eakins Enterprises makes model boats, and it is switching to a lean manufacturing process. At one assembly area, Eakins is using one part container that holds 240 parts, and it wants the output to be approximately 80 finished parts per hour; they also desire a 20 percent safety stock for this part. How fast will the container have to make it through the system to accomplish this? Do not round intermediate calculations. Round your answer to two decimal places.
Chapter 14 Solutions
Operations Management
Ch. 14.S - Prob. 1DRQCh. 14.S - Prob. 2DRQCh. 14.S - Prob. 3DRQCh. 14.S - Prob. 4DRQCh. 14.S - Prob. 5DRQCh. 14.S - Prob. 6DRQCh. 14.S - Prob. 7DRQCh. 14.S - Prob. 8DRQCh. 14.S - Prob. 9DRQCh. 14.S - Prob. 10DRQ
Ch. 14.S - The probability that equipment used in a hospital...Ch. 14.S - The frequency of breakdown of a machine that...Ch. 14.S - Prob. 3PCh. 14 - Prob. 1DRQCh. 14 - Prob. 2DRQCh. 14 - Prob. 3DRQCh. 14 - Prob. 4DRQCh. 14 - Prob. 5DRQCh. 14 - Prob. 6DRQCh. 14 - Prob. 7DRQCh. 14 - Contrast push and pull methods ofmovi.ttg goods...Ch. 14 - Prob. 9DRQCh. 14 - Prob. 10DRQCh. 14 - Prob. 1TSCh. 14 - Prob. 2TSCh. 14 - Prob. 3TSCh. 14 - Prob. 1CTECh. 14 - Prob. 2CTECh. 14 - Prob. 1PCh. 14 - Prob. 2PCh. 14 - Prob. 3PCh. 14 - Determine the number of cycles per day and the...Ch. 14 - Given this set of daily service operations, and...Ch. 14 - Determine the number of cycles per day and a...Ch. 14 - Compute the takt time for a system where the total...Ch. 14 - Prob. 8PCh. 14 - Prob. 9PCh. 14 - What might Stephanie determine as the best...
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- A 10 station automated assembly system produces an ideal cycle time (Tc) of 14 seconds/cycle. When a defective part enters any assembly station it sometimes causes a station jam or stoppage. Defective parts occur at a rate of 0.07 and a jams due to defective parts occur at a rate of 0.4. When a jam occurs, it takes on average 74 seconds to clear and restart the station. Determine the production rate of acceptable parts (Rap) to the nearest 1 part/hour.arrow_forwardCompare and contrast the following two situations: A company's lean system stress teamwork. Employees feel more involved and, therefore, productivity and quality increase at the company. The problem is that workers also experience a loss of individual autonomy. A humanities professor believes that all students want to learn. To encourage students to work together and learn from each other--thereby increasing the involvement, productivity, and the quality of the learning experience--the professor announces that all students in the class will receive the same grade and that it will be based on the performance of the group.arrow_forwardExamples of companies that have used SMED One example of a company that succeeded with this system was Toyota, achieving a significant time reduction. Toyota used to take more than four hours to change models on an 800-ton stamping press, when its equivalent at Volkswagen required only two hours. Mention another company that has been successful with this system (SMED).arrow_forward
- Japanese companies that have used just-in-time (JIT) for five or more years are reportingbclose to a 30 per cent increase in labour productivity, a 60 per cent reduction in inventories, a 90 per cent reduction in quality rejection rates, and a 15 per cent reduction in necessary plant space. However, implementing a just-in-time system does not occur overnight. It took Toyota over twenty years to develop its system and realize significant benefits from it. Source: Sumer C. Aggrawal, Harvard Business Review Requirements(a) Explain how the benefits claimed for JIT in the above quotation are achieved and why it takes so long to achieve those benefits.(b) Explain how management information systems in general (and management accounting systems in particular) should be developed in order to facilitate and make best use of JIT. Note: Ensure the work you present is clearly referenced and failure to do so will elicit a loss of marksarrow_forwardnorth end coffee roasters roast 300bags of coffee per day in three shifts at an average rate of 63 bags/hour. during the first shift, 100bags of coffee are roasted at 63bags/hour and the next 100 bags are roasted at 72 bags/hour in the second shift. Q- after roasting each bag of coffee is sealed and labelled at the packaging stage at a rate of 90 bags/hour. what is the average rate of production for the entire process pf roasting and packaging coffee beans at north end?arrow_forwardAssume that a plant operates 2,000 hours per year and the demand rate for parts is 100,000 units per year. The circulation time for each kanban container is 24 hours.a. How many kanban containers are needed for a container size of 100 parts?b. What would be the effect of reducing the container size to 60 parts?c. What is the takt time for this process?d. What takt time is needed for 80,000 units per year?arrow_forward
- A U.S. Postal Service supervisor is looking for ways to reduce stress in the sorting department. With the existing arrangement, stamped letters are machine-canceled and loaded into tubs with 375 letters per tub. The tubs are then pushed to postal clerks, who read and key zip codes into an automated sorting machine at the rate of 1 tub per 375 seconds. To overcome the stress caused when the stamp canceling machine outpaces the sorting clerks, a pull system is proposed. When the clerks are ready to process another tub of mail, they will pull the tub from the canceling machine area. How many tubs should circulate between the sorting clerks and the canceling machine if 90,000 letters are to be sorted during an 8-hour shift, the safety stock policy variable, α, is 0.18, and the average waiting time plus materials handling time is 25 minutes per tub?arrow_forwardJapanese companies that have used just-in-time (JIT) for five or more years are reporting close to a 30 per cent increase in labour productivity, a 60 per cent reduction in inventories, a 90 per cent reduction in quality rejection rates, and a 15 per cent reduction in necessary plant space. However, implementing a just-in-time system does not occur overnight. It took Toyota over twenty years to develop its system and realize significantbenefits from it.Source: Sumer C. Aggrawal, Harvard Business ReviewRequirements(a) Explain how the benefits claimed for JIT in the above quotation are achieved and whyit takes so long to achieve those benefits. (b) Explain how management information systems in general (and management accounting systems in particular) should be developed in order to facilitate and make best use of JIT.arrow_forwardIs it accurate to say that lean management has a propensity to ignore some aspects of an organization's efficiency? Assuming that to be the case, what are some of the possible unfavorable outcomes of these procedures that might seriously compromise the effectiveness of your organization?arrow_forward
- The Worthington Gear Company installed a bank of 10 robots about three years ago. The robots greatly in-creased the firm’s labor productivity, but recently attention has focused on maintenance. The firm does no pre-ventive maintenance on the robots because of the variability in the breakdown distribution. Each machine hasan exponential breakdown (or interarrival) distribution with an average time between failures of 200 hours. Eachmachine hour lost to downtime costs $30, which means that the firm has to react quickly to machine failure.The firm employs one maintenance person, who needs 10 hours on average to fix a robot. Actual maintenancetimes are exponentially distributed. The wage rate is $10 per hour for the maintenance person, who can be putto work productively elsewhere when not fixing robots. Determine the daily cost of labor and robot downtime.arrow_forwardA JIT system uses kanban cards to authorize movement of incoming parts. In one portion of the system, a work center uses an average of 98 parts per hour while running. The manager has assigned an inefficiency factor of .28 to the center. Standard containers are designed to hold 6 dozen parts each. The cycle time for parts containers is about 105 minutes.arrow_forward8. The Timken Company applied Six Sigma tools to minimize process variation to address the ______________ principle of lean operating systems. elimination of waste increased speed and response improved quality reduced cost 9. Southwest Airlines' customers wait on a first-come, first-served basis and board in zones to address the ____________principle of lean operating systems. elimination of waste increased speed and response improved quality reduced cost 10. Traditional factories use a push system, which ___________________________ eliminates waste by reducing the number of parts per workstation produces finished-goods inventory in advance of customer demand using a forecast of sales relies on employees to monitor, encourage, and train one another to create a system of trust uses conveyor belt technologies to move parts, inventory, and partially processed goods to the next workstation 11.The concept of _________________ characterizes a pull system. assigning…arrow_forward
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