Lean System and
scheduling
BY: USER_CHOGWO
, Question:
1. Stan Weakly can sort a bin of 100 letters in 10 minutes. He typically receives 600 letters
an hour. A truck arrives with more bins every 30 minutes. The office uses a safety factor of
10%. How many kan bans are needed for the letter-sorting process?
Solution:
d = 600
L = 30 min = 0.5 hours
S = 0.10 (600 x 0.5) = 30
C = 100
N = (600 x .05) + 30 = 3.3 kanbans
100
3.3 kanbans are needed for the letter-sorting process. This means 3 containers plus 1/3 of another
container would be used.
2. How did lean production evolve into a system of continuous improvement?
Solution:
Transforming from a traditional push production to a state‐of‐the‐art pull production is
often considered a fundamental change towards Lean production. As observed in the boat
production game, in a pull system, excess WIP inventory and unnecessarily long cycle time
(obvious muda) is significantly reduced to drive down the cost. It can also be observed that
process variability is also reduced. With such a clean production, we often can have better
quality, safer working environment, better customer service, and better flexibility, as well. The
scheduling
BY: USER_CHOGWO
, Question:
1. Stan Weakly can sort a bin of 100 letters in 10 minutes. He typically receives 600 letters
an hour. A truck arrives with more bins every 30 minutes. The office uses a safety factor of
10%. How many kan bans are needed for the letter-sorting process?
Solution:
d = 600
L = 30 min = 0.5 hours
S = 0.10 (600 x 0.5) = 30
C = 100
N = (600 x .05) + 30 = 3.3 kanbans
100
3.3 kanbans are needed for the letter-sorting process. This means 3 containers plus 1/3 of another
container would be used.
2. How did lean production evolve into a system of continuous improvement?
Solution:
Transforming from a traditional push production to a state‐of‐the‐art pull production is
often considered a fundamental change towards Lean production. As observed in the boat
production game, in a pull system, excess WIP inventory and unnecessarily long cycle time
(obvious muda) is significantly reduced to drive down the cost. It can also be observed that
process variability is also reduced. With such a clean production, we often can have better
quality, safer working environment, better customer service, and better flexibility, as well. The
