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HeijunkaSistema de Manufactura de Johnson Controls
Capacity Planning rev 2.ppt
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
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
HeijunkaCales son los beneficios visuales que Heijunka le puede traer al rea de produccin?
Capacity Planning rev 2.ppt
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
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
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
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%
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
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
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%
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
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
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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