Q11.1 (Three Step) Consider a worker-paced line with three process steps, each o
ID: 462809 • Letter: Q
Question
Q11.1 (Three Step) Consider a worker-paced line with three process steps, each of which is
staffed with one worker. The sequence of the three steps does not matter for the completion of the product. Currently, the three steps are operated in the following sequence.
Activity time
Step #1 = 3 min/unit Step #2 = 4 min/unit Step #3 = 5min/unit
a. What would happen to the inventory in the process if the process were operated as a push system?
b. Assuming you would have to operate as a push system, how would you resequence the three activities?
c. How would you implement a pull system?
Explanation / Answer
a). If the process were operated as a push system, then there would be WIP pile up at station 1 and 2, because of the high throughput rate of these work stations.
b). To operate as a push system, the three processes would be resequenced in reverse order - Operation 3, Operation 2 and Operation 1.
c) Pull system would be implemented using Kanban, replenishing point of use inventory using a Kanban system at each station. As bins will be implemented, the empty bin will be used a signal to replenish material. As material will be consumed, a trigger will be reached indicated by the number of bins remaining. when the trigger point would be reached Kanban card would be pulled and delivered to preceding station.
The Kanban would be placed on a scheduling board in sequence. Production would run as per Kanban on the scheduling board.
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