Question 1 A company is producing chairs. To produce one chair in Workstation A,
ID: 383597 • Letter: Q
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Question 1 A company is producing chairs. To produce one chair in Workstation A, 4 metal bars are required. In each 12-hour work day, Workstation A produces 480 chairs. Metal bars are produced in Workstation B. Workstation A and B are located in different areas of the plant and a two card pull system is used. The information about production and moving metal bars is shown below; .Container Size: 120 units Conveyance Total wait time: 2.5 hours Total move time: 1 hours o o Production o Total wait time: 0.75 hours o Setup time: 0.9 hours/container o Processing time: 0.005 hours/unit Safety margin: 20% How many conveyance and production cards are needed for metal bars? a) b) What should be the minimum container size in order to reduce the number of conveyance cards by 50%? Question 2 What are the main advantage and disadvantage of having greater number of kanban cards in a production system? What are the objectives in JIT regarding setup times and lot sizes? Briefly discuss main differences between Romantic and Pragmatic JIT. b) c) d)Explanation / Answer
2) b) Advantages of Kanban
It is useful for optimizing inventory and reducing product obsolescence. It is useful for fitting in the kaizen system for continuous improvement. It is useful for product designs to be upgraded in small increments.
It helps to reduce waste and scrap as only the ones that are needed are manufactured. It helps to cut down on overproduction.
It helps for producing flexibility in production and kanban ensures that it is not stuck with the problem of excess inventory.
It helps to increase output in an effective manner and wait time is also reduced.
The total cost is also reduced by preventing over production.
Disadvantages of Kanban:
1. It is not so effective for shared resource situations. It is important to have a bigger for ensuring downstream station and the system doesn't become too complicated.
It is also useful in the case of demand and cause problems as it ends up assuming stable repetitive production plans.
It is also not useful for manufacturing environment that has short production runs.
The breakdown in the system can cause the shutdown of entire system.
C) The objectives of JIT includes producing only the services and products that are needed by the customer.
It also includes producing products as quickly as they can for the customers to use them in setup roles and on perfect quantity.
There is also focus on perfect quality and quantity.
The focus is on minimum possible time production and no wastage of Labour materials.
D) Romantic JIT has different slogans and idealistic goals which includes lot size of one, zero inventories and defects that are zero.
Pragmatic JIT has set of techniques that are technical in a fair amount and related to machine change over, design of layout, simplification of product, quality training and maintenance of equipment.
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