3. Recalculate what the new number of production cards should be, and estimate how many hours’ worth of inventory this would equal. Because of her success in setting up a kanban system in workcell H, Ann has been brought over to help to fix the kanban system at workcell K.According to workcell K’s current production manager, Tom Tucker, “We’re swimming in inventory here. I thought I calculated the right number of production cards, but something must have changed.”

Tom provides Ann with the information he used to determine the number of production cards:

Assumed demand rate, D
260 units per hour Lead time, T
2 hours Container size
50 units Safety factor, x
5%

Tom notes, “Of course, there have been a few changes, but they’re really no big deal.

Demand is off slightly, down to 220 units an hour, and we’ve increased the container size to 100 units. But I can’t see that making much of a difference.”