In this case the cycle time and the takt time is the same, remember that the takt time is the pace at which the products must be made to meet the daily customer demand, if the takt time would be required to be perhaps at half, then to meet the new customer demand the cells should be doubled, do not confuse takt time with cycle time.
In other words the number of operators required for a given cycle time and takt time is:
Total Number of Operators = (Total Cycle Time) / (Takt Time), for this case: = (152) /(38) = 4
Controlling Upstream Production Flow
After the improvement methods have been realized in each operation of the future state mapping, (see Future Stream Mapping) now it is time to define how to control the upstream production flow, the team has concluded that the following supermarkets are necessary to assure a smooth production flow:
On the Future Value stream Mapping we have added the following supermarkets.
Leveling Production Flow
to meet production flow requirements in a smooth manner, we have to select what method to use to achieve this, two alternatives methods are possible one is heijunka and the other one is paced withdrawal:
Heijunka when to use it:
This system is used based on volume and products variety
Paced withdrawal when to use it:
Used on small lot production and for identical products and with same pitch increments.
1- Define method to be used heijunka or paced withdrawal design the appropriate kanban system.
2- Define the improvement methodologies to be used
3- Define the information and production flow along with the material runner path