ABC Ltd. manufactures three parts: X, Y, and Z. Orders are on hand to deliver a total of 45,000 parts to various customers over the next four-week period. The part number breakdown is 4,500 of X; 22,500 of Y; and 18,000 of Z. The plant producing these parts works two eight-hour shifts (with a 10% allowance for downtime), five days per week.
A. Design a heijunka production sequence for these parts, assuming cellular manufacturing and a scheduling unit of one shift.
b. What is the takt time for this process?
c. what is the length of a production cycle for this process?
d. How many times will this cycle be repeated during a shift?