You decide that before \"traditional\" lean techniques are implemented in your c

Question

You decide that before "traditional" lean techniques are implemented in your current "push" process, some Factory Physics improvements must be made to reduce variability and lower lot sizes in order to reduce current WIP inventory between stations. After these improvements have been made, then you can do an internal benchmark using the "basics" of Factory Physics on the revised production process to find out what is theoretically "physically" possible in terms of critical work in process (W_0) and throughput (TH_PWC). You obtained the following data after greatly reducing the in-process inventory (lowered CT from many days to a few days): The bottleneck rate (r_b) of the line is 60 units/hour The average time for a unit to be processed from input to the first station to exit at the last station is now 50 hours (CT) The raw processing time (T_0) is measured by stopwatch to be 2 hours. Customer demand is 7200 units per month (assume 20 work days per month with 7 hours per day work time available). You measured the average production throughput (TH) at 40 jph. Calculate (and, enter only the number into the first 3 boxes that follow): The critical work in process, W_0; and, using Little's Law determine the average WIP; and, then determine TH_PWC (round your answer to the nearest jph). Compare with Customer Demand to see if the Factory Physics "lean" techniques will allow the current line to be "lean" and make production (enter, either yes or no into the 4th box).

Explanation / Answer

Critical work in progress Wo=rb&*To

                                                2*60= 120 units

Average WIP = Average output from process /Throughput X Average Processing Time

                                7200/40*2

                                =3800

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