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    Answers To Extra Exercises LEAN - EN

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    ziedtt

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    © All Rights Reserved
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    Answers To Extra Exercises LEAN - EN

    Uploaded by

    ziedtt
    10 views1 page

    Original Title

    Answers to Extra Exercises LEAN_EN

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    10 views1 page

    Answers To Extra Exercises LEAN - EN

    Uploaded by

    ziedtt

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    QUESTIONS WITH SOLUTIONS

    1. Calculate the Process Lead Time in days for the following process. This is a production process for
    wooden toys. Given that the current work in progress is 600 pieces and we know that every 3 hours
    there are 4 toys finished. 1 working day consists of 7,5 work hours.
    ProcesLeadTime = WorkInProgress/ExitRate; WIP = 600 pieces
    Exit Rate =4 pieces/3h
    PLT = 600pieces/(4pieces/3hours) = 450 hours
    450 hours = 450/7,5 = 60 days
    2. Please calculate the takt time in minutes for a police department processing speeding tickets in a big
    city. This department works on a 5-shift basis (24/24, 7days a week). Each week they receive 2520
    tickets to be processed.
    Takt time = Available time / Customer demand in that time
    Available minutes in a week = 7x24x60 = 10080 minutes
    Takt = 10080 minutes / 2520 = 4 minutes
    3. Please calculate the Process Cycle efficiency for the following process? Each crime-investigation (armed
    robbery) consists of 16 hours of valuable work (filing the police report, processing inputs, analyzing
    circumstances, preparing the case and judging the delinquent). However, the average lead time
    between crime and conviction is taking 6,6 months. Note that 1 month can be considered as 20 working
    days.
    Proces Cycle Efficiency=CustomerValueAdd time/ProcesLeadTime x 100%
    CVA time = 16 hours = 2 days
    PLT = 6,6 months = 6,6 x 20 working days per month = 132 days
    PCE =2 days / 132 days = 1,5%
    4. A Magistrates Court works 5 days each week from 8am till 6pm. On average they will take half an hour
    lunch break each day. Trials are held in parallel in the 3 Court rooms. The Registry department is
    responsible for supplying all necessary files. There is a weekly average of 95 trials per Court room.
    a. What is the takt time for the Registry in minutes?
    i. 30 minutes
    ii. 10,5 minutes
    iii. 10 minutes
    iv. 0,1 minutes
    Available time = 5 x 9,5 = 47,5 hours. Requests per week = 3 x 95 = 285 requests. Takt time =
    47,5*60minutes / 285 = 10 minutes
    b. In general the Registry department has approximately 8550 of cases in progress for this Court.
    What is the Process Lead Time for one case (in working days)?
    i. 50 days
    ii. 150 days
    iii. 210 days
    iv. 80 days

    PLT=WIP/Exit Rate
    WIP=8550, exit rate = 285/week => 57/workday
    PLT=8550/57 = 150 working days

    c. Treating one case typically consists of 12 hours of ‘Value Add’ time. What is the current PCE%
    based on the answer above?

    CustomerValueAdd Time: 12 hours


    ProcesLeadTime = 150 days x 8 hours=1200 hours.
    PCE%=CVA time/PLT = 12/1200*100% = 1%
    d. If the Registry department wishes to improve their PCE% towards 5%, what should their
    maximum allowable Work in Progress be (WIP cap) for the cases?

    Increasing the PCE% by a factor of 5 equals reducing the WIP by a factor of 5. So 8550/5=1710 cases.

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