1. A manager wants to determine the number of containers to use for incoming parts for a kanban system to be installed next month. The process will have a usage rate of 80 pieces per hour. Because the process is new, the manager has assigned an inefficiency factor of .35. Each container holds 45 pieces, and it takes an average of 75 minutes to complete a cycle. How many containers should be used? As the system improves, will more or fewer containers be required? Why?
1. A manager wants to determine the number of containers to use for incoming parts for a kanban system to be installed next month. The process will have a usage rate of 80 pieces per hour. Because the process is new, the manager has assigned an inefficiency factor of .35. Each container holds 45 pieces, and it takes an average of 75 minutes to complete a cycle. How many containers should be used? As the system improves, will more or fewer containers be required? Why?
Practical Management Science
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ISBN:9781337406659
Author:WINSTON, Wayne L.
Publisher:WINSTON, Wayne L.
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![**Kanban System Container Calculation Example**
A manager wants to determine the number of containers to use for incoming parts for a kanban system to be installed next month. The process will have a usage rate of 80 pieces per hour. Because the process is new, the manager has assigned an inefficiency factor of 0.35. Each container holds 45 pieces, and it takes an average of 75 minutes to complete a cycle.
### Problem Statement:
How many containers should be used? As the system improves, will more or fewer containers be required? Why?
### Detailed Explanation:
**1. Determine the Usage Rate:**
- The usage rate is given as \( 80 \) pieces per hour.
**2. Calculate the time to complete a cycle:**
- The time to complete a cycle is given as 75 minutes. Convert this into hours:
\[
\frac{75 \text{ minutes}}{60 \text{ minutes/hour}} = 1.25 \text{ hours}
\]
**3. Calculate the Total Requirement Considering Inefficiency Factor:**
- First, calculate the requirement without the inefficiency factor:
\[
\text{Usage Rate} \times \text{Cycle Time} = 80 \text{ pieces/hour} \times 1.25 \text{ hours} = 100 \text{ pieces}
\]
- Next, introduce the inefficiency factor of 0.35 (or 35%):
\[
100 \text{ pieces} \times (1 + 0.35) = 100 \text{ pieces} \times 1.35 = 135 \text{ pieces}
\]
**4. Determine the Number of Containers:**
- Each container holds 45 pieces. To find the number of containers required:
\[
\frac{135 \text{ pieces}}{45 \text{ pieces/container}} = 3 \text{ containers}
\]
### Future Requirement Analysis:
As the system improves, the inefficiency factor is expected to decrease. This means that the total requirement for parts will reduce, and as a result, fewer containers will be required. Specifically:
- If the inefficiency factor decreases, the total number of pieces needed decreases.
- Consequently, the number of containers required to meet the demand will also decrease.
Understanding and analyzing these calculations helps in effectively planning and managing resources in a kanban system.](/v2/_next/image?url=https%3A%2F%2Fcontent.bartleby.com%2Fqna-images%2Fquestion%2Facd715aa-a0f0-49fa-862e-65f9ebf46d46%2F69e94358-0cf0-498c-9ad0-07743b859c1d%2Fnf0znvb_processed.png&w=3840&q=75)
Transcribed Image Text:**Kanban System Container Calculation Example**
A manager wants to determine the number of containers to use for incoming parts for a kanban system to be installed next month. The process will have a usage rate of 80 pieces per hour. Because the process is new, the manager has assigned an inefficiency factor of 0.35. Each container holds 45 pieces, and it takes an average of 75 minutes to complete a cycle.
### Problem Statement:
How many containers should be used? As the system improves, will more or fewer containers be required? Why?
### Detailed Explanation:
**1. Determine the Usage Rate:**
- The usage rate is given as \( 80 \) pieces per hour.
**2. Calculate the time to complete a cycle:**
- The time to complete a cycle is given as 75 minutes. Convert this into hours:
\[
\frac{75 \text{ minutes}}{60 \text{ minutes/hour}} = 1.25 \text{ hours}
\]
**3. Calculate the Total Requirement Considering Inefficiency Factor:**
- First, calculate the requirement without the inefficiency factor:
\[
\text{Usage Rate} \times \text{Cycle Time} = 80 \text{ pieces/hour} \times 1.25 \text{ hours} = 100 \text{ pieces}
\]
- Next, introduce the inefficiency factor of 0.35 (or 35%):
\[
100 \text{ pieces} \times (1 + 0.35) = 100 \text{ pieces} \times 1.35 = 135 \text{ pieces}
\]
**4. Determine the Number of Containers:**
- Each container holds 45 pieces. To find the number of containers required:
\[
\frac{135 \text{ pieces}}{45 \text{ pieces/container}} = 3 \text{ containers}
\]
### Future Requirement Analysis:
As the system improves, the inefficiency factor is expected to decrease. This means that the total requirement for parts will reduce, and as a result, fewer containers will be required. Specifically:
- If the inefficiency factor decreases, the total number of pieces needed decreases.
- Consequently, the number of containers required to meet the demand will also decrease.
Understanding and analyzing these calculations helps in effectively planning and managing resources in a kanban system.
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