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A manufacturing assembly line has a demand for specific part of 1,200 parts per eight-hour day....

A manufacturing assembly line has a demand for specific part of 1,200 parts per eight-hour day. It wants to design a lean system using containers. It takes about four hours to round-trip a container from one work center to the next and back again. It also wants to hold 10% safety stock of this part in its system.

a) Design a container system. State each container's size and how many are needed.

b) Calculate the maximum system inventory for this part.

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Answer #1

1-

Assuming this is 2 bin system

Where,

Cc = Container Capacity

Dp = Average Period Demand = 1200

Tl = Lead Time = 4 hour

Fs = Factor of Safety = 1.1

K= Number of containers = 2 (Assuming this is 2 bin Kanban system)

Cc= (1200 * 4 * 1.1)/ 2

= 2640

Answer - 2 bins are needed. Each of size 2640

2. Maximum system inventory would be sum of capacities of two bins

= 2640*2

= 5280

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