13 Heijunka - Heijunka 1 Example 1 A manufacturing facility...

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Heijunka 1 Heijunka 1
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Example 1 Example 1 A manufacturing facility produces 3 parts. Each part must be processed through cut, mold, and assembly. Setup and processing times for each part at each machine can be determined. Schedule parts considering available labor/machine times, efficiency and the daily demand for each part. Daily demand matrix: 40-Day Demand Daily Demand Part A 1000 parts 25 parts Part B 2000 parts 50 parts Part C 3000 parts 75 parts Setup time matrix: Daily demand = 40-day demand / 40 Machine Parts Cut (min) Mold (min) Assembly (min) A 10 5 2 B 4 3 6 C 1 2 4 (e.g. It takes 10 min. to setup the cut machine to cut part A. It takes 4 min. to setup the assembly machine to assemble part C)
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Example 1 Example 1 Processing time matrix: Machine Parts Cut (min) Mold (min) Assembly (min) A 5 4 2 B 3 6 6 C 4 2 4 (e.g. It takes 5 min. for cut machine to cut 1 part of A. It takes 4 min. to assemble 1 part C.) Available time matrix: Working time per shift No. of shifts per day No. of machine allocated Total working time per day (min) Efficiency Total available time per day (min) Cut 480 min (8 hrs) 2 1 960 95% 912 Mold 480 min (8 hrs) 2 1 960 100% 960 Assembly 480 min (8 hrs) 2 1 960 100% 960 Total working time per day = working time per shift * no. of shifts per day * no. of machines allocated Total available time per day = Total working time per day * efficiency
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Example 1 Example 1 Part A Part B Part C Daily demand 25 50 75 Ratio 1 : 2 : 3 Ratios determine how many times should each part be repeated within in one production cycle. C C C B B A There will be (1+2+3=) 6 slots for parts in one production cycle. (or may be 7 slots including one empty slot for `Made to Order`s.) This production cycle will repeat itself through the day. The production cycle sequence, will be a bad sequence of parts since Part Cs will be accumulating.
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Example 1 Example 1 What is the ideal sequence?
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