12 Heijunka Esp
Transcript of 12 Heijunka Esp
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HeijunkaSistema de Manufactura de Johnson Controls
Capacity Planning rev 2.ppt
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ObjetivosUsted podr definir qu es Heijunka
Entender dnde utilizar Heijunka y las diferentes formas de aplicarlo en produccin
Aprender los elementos de Heijunka y cmo son utilizados
Har algunas simulaciones de Heijunka
Capacity Planning rev 2.ppt
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HeijunkaCul es la definicin de Heijunka?
Dnde debe ser aplicado en Produccin?
Quin es responsable de que la herramienta heijunka tenga impacto?
Capacity Planning rev 2.ppt
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HeijunkaCales son los beneficios visuales que Heijunka le puede traer al rea de produccin?
Capacity Planning rev 2.ppt
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Heijunka : Elementos VisualesElementos Visuales de Heijunka:Nmeros de parte horizontalmenteTiempo Takt / Tiempo PitchTiempo de ruta verticalmente (usualmente en incrementos de pitch)Retrasos / Stock de Seguridad Construccin del Buffer / Jalar el BufferBarra de ritmo de trabajo Secuencia de Manufactura (Frecuencia de ciclo)Instrucciones de produccin / Kanban de retiro
Capacity Planning rev 2.ppt
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Heijunka : Tiempo de rutaLa Ruta -
Cuando se carga Heijunka el # of pitches por ruta se determina por el tiempo elemental requerido para retirar material y reabastecer la lnea.
Entre ms cercana la ruta de reabastecimiento, el menor nmero de pitches requeridos para cada ruta.
Ejemplo: Si la ruta tiene 11 minutos de recorrido y el pitch es de 6 minutos. En cunto tiempo se tiene que establecer la ruta?
Capacity Planning rev 2.ppt
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Heijunka : EjemploDado el siguiente ejemplo, cmo cargara el tablero de Heijunka si usted tiene una frecuencia de ciclo de 1 (o manufacturar cada parte una vez por da)?
Capacity Planning rev 2.ppt
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Capacity Planning rev 2.ppt
Question
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:8hours146.820
Finshed Pack:10pcs156.360
Forecast:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
Finalized takt time:
Total Operators Required:
Total Hours per shift:
Pitch Time:
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Answer
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:7.5hours146.820
Finshed Pack:10pcs156.360
Total Demand:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
2 Possible Answers:
Finalized takt time:21or17
Total Operators Required:78
Total Hours per shift:97.5
Pitch Time:3.22.8
Data needed:
Total Sec648000540000
Total Planned DT7920079200
Total Avail Prod Sec568800460800
Takt Time21.017.0
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Quiz Questions
1.What is the Takt Time?
Weekly Avail Time =105hrs
Weeks Demand =40000pcs
Takt Time =9.45sec
2.What is the Takt Time?
Two 8 hour Shifts / day
7 hrs avail prod time / shft
Weekly Demand =20000
Takt Time =0
Sheet3
Hoja de Clculo para construccin del programa de Heijunka
Determine el programa de Heijunka para el da:
Cantidad a embarcar
Nivel Total a producir:20 ContenedoresHoy
Piezas Por Contenedor:24 PiezasV110
Tiempo Takt:1 MinV25
Tiempo Pitch:24 minV33
Frecuencia de ciclo:1V42
ContenedoresContenedores+ Buffer-Buffer
Parte%ProgramadosEmbarcadosDentroFuera
V150%-=o
V225%-=o
V315%-=o
V410%-=o
Parte #Porc %7:00 AM7:24 AM7:48 AM8:12 AM8:36 AM9:00 AM9:24 AM9:48 AM10:12 AM10:36 AM11:00 AM11:24 AM11:48 AMComida12:36 PM1:00 PM1:24 PM1:48 PM2:12 PM2:36 PM3:00 PMJalar del Buffer
V150%
V225%
V315%
V410%
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Capacity Planning rev 2.ppt
Question
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:8hours146.820
Finshed Pack:10pcs156.360
Forecast:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
Finalized takt time:
Total Operators Required:
Total Hours per shift:
Pitch Time:
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Answer
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:7.5hours146.820
Finshed Pack:10pcs156.360
Total Demand:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
2 Possible Answers:
Finalized takt time:21or17
Total Operators Required:78
Total Hours per shift:97.5
Pitch Time:3.22.8
Data needed:
Total Sec648000540000
Total Planned DT7920079200
Total Avail Prod Sec568800460800
Takt Time21.017.0
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Quiz Questions
1.What is the Takt Time?
Weekly Avail Time =105hrs
Weeks Demand =40000pcs
Takt Time =9.45sec
2.What is the Takt Time?
Two 8 hour Shifts / day
7 hrs avail prod time / shft
Weekly Demand =20000
Takt Time =0
Sheet3
Hoja de Clculo para construccin del programa de Heijunka
Determine el programa de Heijunka para el da:
Cantidad a embarcar
Nivel Total a producir:20 ContenedoresHoy
Piezas Por Contenedor:24 PiezasV110
Tiempo Takt:1 MinV25
Tiempo Pitch:24 minV33
Frecuencia de ciclo:1V42
ContenedoresContenedores+ Buffer-Buffer
Parte%ProgramadosEmbarcadosDentroFuera
V150%10-10=0o0
V225%5-5=0o0
V315%3-3=0o0
V410%2-2=0o0
Parte #Porc %7:00 AM7:24 AM7:48 AM8:12 AM8:36 AM9:00 AM9:24 AM9:48 AM10:12 AM10:36 AM11:00 AM11:24 AM11:48 AMComida12:36 PM1:00 PM1:24 PM1:48 PM2:12 PM2:36 PM3:00 PMJalar del Buffer
V150%XXXXXXXXXX
V225%XXXXX
V315%XXX
V410%XX
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Heijunka : EjemploAhora intente el mismo ejemplo con un cambio de programacin para algunas partes y una frecuencia de ciclo que se incremente a 2.
Capacity Planning rev 2.ppt
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Capacity Planning rev 2.ppt
Question
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:8hours146.820
Finshed Pack:10pcs156.360
Forecast:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
Finalized takt time:
Total Operators Required:
Total Hours per shift:
Pitch Time:
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Answer
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:7.5hours146.820
Finshed Pack:10pcs156.360
Total Demand:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
2 Possible Answers:
Finalized takt time:21or17
Total Operators Required:78
Total Hours per shift:97.5
Pitch Time:3.22.8
Data needed:
Total Sec648000540000
Total Planned DT7920079200
Total Avail Prod Sec568800460800
Takt Time21.017.0
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Quiz Questions
1.What is the Takt Time?
Weekly Avail Time =105hrs
Weeks Demand =40000pcs
Takt Time =9.45sec
2.What is the Takt Time?
Two 8 hour Shifts / day
7 hrs avail prod time / shft
Weekly Demand =20000
Takt Time =0
Sheet3
Hoja de Clculo para construccin del programa de Heijunka
Determine el programa de Heijunka para el da:
Cantidad a embarcar
Nivel Total a producir:20 ContenedoresHoy
Piezas Por Contenedor:24 PiezasV113
Tiempo Takt:1 MinV24
Tiempo Pitch:24 minV33
Frecuencia de ciclo:2V43
ContenedoresContenedores+ Buffer-Buffer
Parte%ProgramadosEmbarcadosDentroFuera
V150%-=o
V225%-=o
V315%-=o
V410%-=o
Parte #Porc %7:00 AM7:24 AM7:48 AM8:12 AM8:36 AM9:00 AM9:24 AM9:48 AM10:12 AM10:36 AM11:00 AM11:24 AM11:48 AMComida12:36 PM1:00 PM1:24 PM1:48 PM2:12 PM2:36 PM3:00 PMJalar del Buffer
V150%
V225%
V315%
V410%
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Capacity Planning rev 2.ppt
Question
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:8hours146.820
Finshed Pack:10pcs156.360
Forecast:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
Finalized takt time:
Total Operators Required:
Total Hours per shift:
Pitch Time:
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Answer
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:7.5hours146.820
Finshed Pack:10pcs156.360
Total Demand:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
2 Possible Answers:
Finalized takt time:21or17
Total Operators Required:78
Total Hours per shift:97.5
Pitch Time:3.22.8
Data needed:
Total Sec648000540000
Total Planned DT7920079200
Total Avail Prod Sec568800460800
Takt Time21.017.0
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Quiz Questions
1.What is the Takt Time?
Weekly Avail Time =105hrs
Weeks Demand =40000pcs
Takt Time =9.45sec
2.What is the Takt Time?
Two 8 hour Shifts / day
7 hrs avail prod time / shft
Weekly Demand =20000
Takt Time =0
Sheet3
Hoja de Clculo para construccin del programa de Heijunka
Determine el programa de Heijunka para el da:
Cantidad a embarcar
Nivel Total a producir:20 ContenedoresHoy
Piezas Por Contenedor:24 PiezasV113
Tiempo Takt:1 MinV24
Tiempo Pitch:24 minV33
Frecuencia de ciclo:2V43
ContenedoresContenedores+ Buffer-Buffer
Parte%ProgramadosEmbarcadosDentroFuera
V150%10-13=0o3
V225%5-4=1o0
V315%3-3=0o0
V410%2-3=0o1
Parte #Porc %7:00 AM7:24 AM7:48 AM8:12 AM8:36 AM9:00 AM9:24 AM9:48 AM10:12 AM10:36 AM11:00 AM11:24 AM11:48 AMComida12:36 PM1:00 PM1:24 PM1:48 PM2:12 PM2:36 PM3:00 PMJalar del Buffer
V150%XXXXXXXXXX3
V225%XXXXX
V315%XXX
V410%XX1
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Heijunka : EjemploDebido a que esta lnea obviamente no cambia con las restricciones dadas vamos a cambiar tantas veces como sea posible. Cmo cargara el heijunka en este escenario?
Capacity Planning rev 2.ppt
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Capacity Planning rev 2.ppt
Question
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:8hours146.820
Finshed Pack:10pcs156.360
Forecast:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
Finalized takt time:
Total Operators Required:
Total Hours per shift:
Pitch Time:
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Answer
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:7.5hours146.820
Finshed Pack:10pcs156.360
Total Demand:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
2 Possible Answers:
Finalized takt time:21or17
Total Operators Required:78
Total Hours per shift:97.5
Pitch Time:3.22.8
Data needed:
Total Sec648000540000
Total Planned DT7920079200
Total Avail Prod Sec568800460800
Takt Time21.017.0
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Quiz Questions
1.What is the Takt Time?
Weekly Avail Time =105hrs
Weeks Demand =40000pcs
Takt Time =9.45sec
2.What is the Takt Time?
Two 8 hour Shifts / day
7 hrs avail prod time / shft
Weekly Demand =20000
Takt Time =0
Sheet3
Hoja de Clculo para construccin del programa de Heijunka
Determine el programa de Heijunka para el da:
Cantidad a embarcar
Nivel Total a producir:20 ContenedoresHoy
Piezas Por Contenedor:24 PiezasV110
Tiempo Takt:1 MinV25
Tiempo Pitch:24 minV33
Frecuencia de ciclo:10V42
ContenedoresContenedores+ Buffer-Buffer
Parte%ProgramadosEmbarcadosDentroFuera
V150%-=o
V225%-=o
V315%-=o
V410%-=o
Parte #Porc %7:00 AM7:24 AM7:48 AM8:12 AM8:36 AM9:00 AM9:24 AM9:48 AM10:12 AM10:36 AM11:00 AM11:24 AM11:48 AMComida12:36 PM1:00 PM1:24 PM1:48 PM2:12 PM2:36 PM3:00 PMJalar del Buffer
V150%
V225%
V315%
V410%
-
Capacity Planning rev 2.ppt
Question
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:8hours146.820
Finshed Pack:10pcs156.360
Forecast:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
Finalized takt time:
Total Operators Required:
Total Hours per shift:
Pitch Time:
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Answer
Assmuptions:
Takt Time Matrix
Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required
Normal # of Shifts:2shifts137.340
Hours / Shift:7.5hours146.820
Finshed Pack:10pcs156.360
Total Demand:27,100pcs165.970
175.61628
185.300
Planned Downtime195.020
Stretches10Daily each shift204.770
Break 115Daily each shift214.55527
Break 220Daily each shift224.340
Clean Up12Daily each shift234.150
TPM50Once per week243.980
Wed Update20Wednesdays 1st and 2nd shift253.820
263.67426
*Assume any OT added has 0 planned downtime273.540
283.410
293.290
Assumptions:
Dem Sec / Pc:83
Dem Sec / Pc + 15%:95.45
Question:
What would be the finalized level load plan with the given assumptions.
Provide the info below for your production review meeting with the team.
2 Possible Answers:
Finalized takt time:21or17
Total Operators Required:78
Total Hours per shift:97.5
Pitch Time:3.22.8
Data needed:
Total Sec648000540000
Total Planned DT7920079200
Total Avail Prod Sec568800460800
Takt Time21.017.0
= Avail Time / Cust Demand
(Dem Sec per Pc + 15%)------------------------------ Takt Time
Direct Operators on line used in the elemental time studies
*Off Line Ops include Line Support / Route Person / etc.
Act Op on Line + Act Op Off Line
Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.
Quiz Questions
1.What is the Takt Time?
Weekly Avail Time =105hrs
Weeks Demand =40000pcs
Takt Time =9.45sec
2.What is the Takt Time?
Two 8 hour Shifts / day
7 hrs avail prod time / shft
Weekly Demand =20000
Takt Time =0
Sheet3
Hoja de Clculo para construccin del programa de Heijunka
Determine el programa de Heijunka para el da:
Cantidad a embarcar
Nivel Total a producir:20 ContenedoresHoy
Piezas Por Contenedor:24 PiezasV110
Tiempo Takt:1 MinV25
Tiempo Pitch:24 minV33
Frecuencia de ciclo:10V42
ContenedoresContenedores+ Buffer-Buffer
Parte%ProgramadosEmbarcadosDentroFuera
V150%10-10=0o0
V225%5-5=0o0
V315%3-3=0o0
V410%2-2=0o0
Parte #Porc %7:00 AM7:24 AM7:48 AM8:12 AM8:36 AM9:00 AM9:24 AM9:48 AM10:12 AM10:36 AM11:00 AM11:24 AM11:48 AMComida12:36 PM1:00 PM1:24 PM1:48 PM2:12 PM2:36 PM3:00 PMJalar del Buffer
V150%XXXXXXXXXX
V225%XXXXX
V315%XXX
V410%XX
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