Suppose there is a two-machine line, where each machine has a 1 minute operation time. There is also a buffer with 1 Kanban card between the machines.
Part 1 (ALREADY GOT THE ANSWERS, see below with explanation)
a) How many parts are produced in the 1st hour? Assume the buffer is empty at time 0.
R: 59, Machine 1 and 2 can both produce 60 parts/hour. However, machine 2 must wait 1 minute before there is a part two work on. (THAT’S CORRECT)
b) How many parts are produced in the second hour?
R: 60, Now since the buffer machine 2 is continuously fed by machine 1, production rate reaches 60. However, the buffer is still empty. (THAT’S CORRECT)
Part 2 (NEED THE CORRECT ANSWERS)
Suppose now that Machine 1 now fails every hour, 10 minutes into the hour, for 10 minutes.
a) How many parts are produced in the first hour? Assume the buffer is empty.
R: 49 – (THAT’S CORRECT)
b) How many parts are produced if we increase the Kanban count from 1 to 10 in the first hour? Assume the buffer is empty.
*R: 60 – (IT IS INCORRECT) CAN SOME CORRECT THIS
Part 3 (NEED THE CORRECT ANSWERS)
Assuming the same conditions are still in place from part 2. Suppose the second machine fails 40 minutes in the hour, every hour for 10 minutes.
a) Assuming the Kanban size is now 2, and the buffer is empty at time 0. How many parts are produced in the first hour?
*R: 20 – (IT IS INCORRECT) CAN SOME CORRECT THIS
b) If we increase the Kanban to 10, how many parts are produced in the second hour?
*R: 50 – (IT IS INCORRECT) CAN SOME CORRECT THIS
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