1) You are about to develop a Heijunka schedule for four products which are proc

Question

1) You are about to develop a Heijunka schedule for four products which are processed

through four operations in a flow line fashion. The necessary information about

processing times, setup times, resource time availability and demand is given below.

a) Find out the minimum batch sizes that will be feasible for each product.

b) What is the length of this Heijunka cycle?

Processing times table Process 3 Process 4 Process 2 15 Part A Part B Part C Part D Process I1 10 12 13 12 Setup times table Process 4 Process 2 15 Process 3 17 26 Part A Part B Part C Part D Process 1 25 12 13 15 12 23 19 Demand table Demand 40 120 82 238 Part Available processing time table Process Process 1 Process 2 Process 3 Process 4 Available time 4550 4800 4250 4650

Explanation / Answer

In the above problem the total demand for each product in the total available time is provided.
Also the profit per product is not given, hence we have to assume that each product is equally profitable.
Thus the aim is to produce maximum number of units of Product A,B,C and D combined.
Note: This problem is not formulated like a heijunka problem. Since demand is not given in annual/monthly/weekly/daily terms and just total available time is provided. Still we will try to solve this like a Heijunka problem

To find the production ratio we need to divide the demand of each product with that of the demand of the lowest product which in this case if 40 (product A demand). Thus we get,

Thus production should take place in the ratio of 1:3:2.05:5.95. But these are not whole numbers. For all practical purposes the minimum feasible batch size for each product is as follows
A:1
B: 3
C: 2
D: 6

The length of this heijunka cycle would be 614 (Calculation below)

Sequence ABBBCCDDDDDD

. However, in this problem the total available time is given for each workstation. The time available at Process 3 is the minimum that is 4250. Thus we try to find the batch size that would ensure the time at process 3 does not exceed 4250

Thus when we multiply the production ratio with a factor of 32, we get the appropriate batch size of
A: 32
B: 96
C: 66
D: 192

Demand A 40 B 120 C 82 D 238

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