Expert Answer :EIN 4401 Lean Production HW 2 -The demand for a pr

Solved by a verified expert :EIN 4401 Lean ProductionHome Work # 21. The
demand for a product is 1000 units per day. The external setup for a punch
press is approximately 1.75 hours. The internal setup time is 15 minutes. The
facility operates on a single 8-hr shift. The punch press feeds the downstream
operation grinder by placing its lot production into containers of size 50. We
will make the grinder be responsible to inform the punch process for the start
of a new production batch as well as the signal for the material order.Here is additional information about this process:- Kanban
waiting time at the receiving post at grinder is 10 minutes- Kanban
transfer time to punch press ordering post is 15 min- Kanban
wait time at the ordering post 5 minutes- Processing
time at the punch press 0.1 minutes per unit- In process
batch waiting time 10 minutes- Lot
transfer time to final buffer is 0- We want
to build 10 % safety to our card calculations.- Material
kanban waiting time at the grinder receiving post is 7 minutes- Material
kanban transfer time to raw material storage is 13 minutes- Material
kanban waiting time at the raw material post is 18 minutes- Time to
withdraw material for punch press lot size is 12 minutes- Time to
convey the raw material to punch press is 10 minutes- The
system operates 8-hour shift a day.a) Find the
minimum production lot size at the punch press.b) Find the
kanban cycle time at the punch press.c) Where
should the production ordering signal kanban be placed at the grinding station.d) Where the
material ordering kanban be placed at the grinding station.3. Consider
a flow line below The following table provides all the information need for
designing Kanban control or Conwip control on this line. All times are in
minutes. Machines
(all data in minutes) 1 2 3 4 5Kanban waiting at the receiving post 2 3 4 3 2Transfer of Kanban to Ordering Post 5 5 5 5 5Wait at the Ordering Post 6 7 6 5 4Internal Setup time 10 12 14 8 7Unit processing time 1 2 3 2 2Container transfer time to downstream buffer 4 4 4 4 6Waiting time in the buffer 6 4 7 5 4The daily demand is known to be 400 units per day. It is
also known that the batch size for this line is 25 units per container. The
line operates 24 hours each day without breaks.a) Calculate
the needed number of Kanban cards if each station will be controlled by Kanban.
Use 10% safety factor.b) If the
entire line is to be controlled by Conwip system what should be the number of
cards needed. For this, use 10% safety factor, and assume the card travel time
from machine 5 to machine 1 is 10 minutes.c) Which
machine is the bottleneck machine on this line? Why?d) Now
assume that we will implement DBR technique to this line. I.e., the machines
from Machine #1 to the bottleneck machine (inclusive) will be controlled by
Conwip. Once the batch clears the bottleneck machine, it will travel the
remaining machines in a push fashion without any delay (pull-push system).
Calculate the number of cards needed on the Conwip side of the line. Again use
10% for safety factor and assume that the card transfer time from your
bottleneck machine to machine #1 is 10 minutes.2. Consider
the data provided below for three products.Product Selling
price ($) Unit direct material ($) Unit direct labor ($) Unit outsourcing cost ($) Unit
overhead ($) Unit processing time at
the bottleneck (hrs.)A 125 25 35 25 12 1B 250 100 35 25 12 2.5C 200 110 35 25 12 2There is 600 total available machine-hours on the bottleneck
machine. The sales department estimates the maximum sales for each product to
be as follows:A : maximum 70B : maximum 120C : maximum 220a) What is
the unit profit of each product in the sense of classical cost accounting? Show
work.b) What is
the contribution margin of each product in the TOC sense? Show work.c) What is
the best product mix that will maximize the throughput (in the TOC sense)? Show
work.d) Write
down the corresponding LP problem, when solved will give the optimal product
mix.3. Consider the data below: Daily
demand matrix: Parts Daily demand (parts)F08958 A
900F00121 B 1,200000331 C 1,800F51354 D 2,400F09584 E
600F09688 F
300 Setup time matrix: MachineParts Cut (sec) Mold (sec) Assembly (sec)F08958 A 300 2000 90F00121 B 300 300000 90000331 C 300 10 90F51354 D 300 20 90F09584 E 300 20 90F09688 F 300 10 90(e.g. It takes 300 sec. to setup the cut machine to cut part
A.It takes 90 sec. to setup the assembly machine to assemble
part C )Processing time matrix: MachineParts Cut (sec) Mold (sec) Assembly (sec)F08958 A 1 10 20F00121 B 1 10 20000331 C 1 10 20F51354 D 1 10 20F09584 E 1 10 20F09688 F 1 10 20(e.g. It takes 1 sec. for cut machine to cut 1 unit of A.It takes 20 sec. to assemble 1 unit C.) Available
time matrix: Working time per shift No. of
shifts per day No. of
machine allocated Total
working time per day (sec) Efficiency Total
available time per day (sec)Cut 480 min
(8 hrs) 3 111 86,400 85% 73,440Mold 480 min (8
hrs) 3 1
86,400 85% 73,440Assembly 480
min (8 hrs) 3 2 172,800 85% 146,880Total working time per day = working time per shift * no. of
shifts per day * no. of machines allocatedTotal available time per day = Total working time per day *
efficiency a) What are
the daily demand ratios for this problem?b) How many
slots will you have on the repeating production cycle (nA, nB, nC, nD, nE, nF)?
What will be your optimum batch size?c) Given the
number of slots, find the sequencing of these cards so that the most smoothed
our production schedule is at hand.