The following table provides all the information need for designing Kanban control or Conwip control on this line. All times are in minutes. Machines (all data in minutes) 1 2 3 45 Kanban waiting at the 23 receiving post Transfer of Kanban to 5 5 5 515 Ordering Post Wait at the Ordering 167 16 14 Post Internal Setup time 101214817 Unit processing time 2322 Container transfer 4 46 time to downstream buffer Waiting time in the 16 7 14 buffer The daily demand is known to be 400 units per day. It is also known that the batch size for this line is 25 units per container. The line operates 24 hours each day without breaks. a) Calculate the needed number of Kanban cards if each station will be controlled by Kanban. Use 10% safety factor. b) If the entire line is to be controlled by Conwip system what should be the number of cards needed. For this, use 10% safety factor, and assume the card travel time from machine 5 to machine 1 is 10 minutes. c) Which machine is the bottleneck machine on this line? Why? d) Now assume that we will implement DBR technique to this line. I.e., the machines from Machine #1 to the bottleneck machine (inclusive) will be controlled by Conwip. Once the batch clears the bottleneck machine, it will travel the remaining machines in a push fashion without any delay (pull-push system). Calculate the number of cards needed on the Conwip side of the line. Again use 10% for safety factor and assume that the card transfer time from your bottleneck machine to machine #1 is 10 minutes. The following table provides all the information need for designing Kanban control or Conwip control on this line. All times are in minutes. Machines (all data in minutes) 1 2 3 45 Kanban waiting at the 23 receiving post Transfer of Kanban to 5 5 5 515 Ordering Post Wait at the Ordering 167 16 14 Post Internal Setup time 101214817 Unit processing time 2322 Container transfer 4 46 time to downstream buffer Waiting time in the 16 7 14 buffer The daily demand is known to be 400 units per day. It is also known that the batch size for this line is 25 units per container. The line operates 24 hours each day without breaks. a) Calculate the needed number of Kanban cards if each station will be controlled by Kanban. Use 10% safety factor. b) If the entire line is to be controlled by Conwip system what should be the number of cards needed. For this, use 10% safety factor, and assume the card travel time from machine 5 to machine 1 is 10 minutes. c) Which machine is the bottleneck machine on this line? Why? d) Now assume that we will implement DBR technique to this line. I.e., the machines from Machine #1 to the bottleneck machine (inclusive) will be controlled by Conwip. Once the batch clears the bottleneck machine, it will travel the remaining machines in a push fashion without any delay (pull-push system). Calculate the number of cards needed on the Conwip side of the line. Again use 10% for safety factor and assume that the card transfer time from your bottleneck machine to machine #1 is 10 minutes
