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Czech Mate Jake And Dans Marvelous Adventure Case Solution
Carrier and Kallish did perform well at the Kaizen event in the sense that their suggestions are good and fit in with the model that is already working throughout the rest of the plant. But one of the major problems that they forgot to address was how to execute the new plan with the help of the operators. The operators know that they are temporary plus have a different culture and language from them. And they also know that they are students so they did not take their suggestions seriously.
Case Analysis for Czech Mate Jake And Dans Marvelous Adventure
1 (a)
The daily capacity for the current PSEM department is as follows:
Daily Capacity = Number of Resources / Average Time
Calculation for Average Time
Operator |
Time in minutes |
Batch Size |
Average time for operator(minutes) |
Total average time (minutes) |
1 |
301 |
6 |
51.03 |
52.99 |
|
410.75 |
8 |
|
|
|
308.75 |
6 |
|
|
2 |
407 |
8 |
50.88 |
|
|
303.5 |
6 |
|
|
|
307 |
6 |
|
|
3 |
362 |
7 |
54.98 |
|
|
436.5 |
7 |
|
|
|
411 |
8 |
|
|
4 |
384 |
6 |
55.09 |
|
|
361 |
7 |
|
|
|
356.75 |
7 |
|
|
Daily Capacity = 4 / 52.99 = 0.08 per minute
Since the operators have a total of 9 hour workday minus the two 15 minutes break and 2 hour lunch break, they have 8 hours to work
Daily capacity per hour = 0.08 * 60 = 4.53 units per hour
1 (b)
Throughput time is the average time that a unit needs to flow through the process from the entry to the exit.
Time in minutes |
Batch size |
Average time per unit |
301 |
6 |
50.17 |
410.75 |
8 |
51.34 |
308.75 |
6 |
51.46 |
407 |
8 |
50.88 |
303.5 |
6 |
50.58 |
307 |
6 |
51.17 |
362 |
7 |
51.71 |
436.5 |
7 |
62.36 |
411 |
8 |
51.38 |
384 |
6 |
64.00 |
361 |
7 |
51.57 |
356.75 |
7 |
50.96 |
Sum of Average time per unit = 637.58
Throughput time = 637.58 / 12 = 53.13 minutes
1 (c)
(Note): Observation time was first 3 batches so 3 readings
Operator 1 |
Operator 2 |
Operator 3 |
Operator 4 |
Total Time |
Total Average time= total time/12 |
|||||||||
Step 1 |
30.25 |
40 |
29.5 |
40.5 |
29 |
31 |
35.75 |
36.5 |
40.25 |
30 |
35.25 |
34.5 |
412.5 |
34.38 |
step 2 |
73 |
96.5 |
72 |
95.5 |
71.75 |
71 |
85 |
83 |
96 |
72.25 |
83 |
84 |
983 |
81.92 |
step 3 |
66 |
88.5 |
67 |
89 |
65 |
66.5 |
78 |
77 |
87.75 |
65.5 |
77.25 |
76.75 |
904.25 |
75.35 |
step 4 |
23.75 |
32 |
24.25 |
31.5 |
24.5 |
23.5 |
28 |
29 |
32 |
23 |
29 |
28.5 |
329 |
27.42 |
step 5 |
96.25 |
127.75 |
95.75 |
128.5 |
95 |
96.5 |
113 |
111.5 |
128.75 |
96.25 |
112.25 |
112 |
1313.5 |
109.46 |
Motion |
1 |
9 |
7 |
7 |
6.25 |
5 |
7.25 |
6.5 |
7.5 |
5.75 |
6.75 |
7.5 |
76.5 |
6.38 |
Transportation |
4 |
0.5 |
0.75 |
0.75 |
1.25 |
0.75 |
0.5 |
0.75 |
1.25 |
1 |
0.5 |
0.5 |
12.5 |
1.04 |
Waiting |
0 |
16.5 |
12.5 |
14.25 |
10.75 |
12.75 |
14.5 |
0 |
17 |
11.5 |
17 |
13 |
139.75 |
11.65 |
Rework |
|
0 |
0 |
0 |
0 |
0 |
0 |
92.25 |
0 |
78.75 |
0 |
0 |
171 |
14.25 |
Total working time (in minutes) 361.83
Total Idol time (in minutes) 19.06
2 (a)
With the new design the time for Motion, Transportation and Waiting would all be eliminated
Operator |
Time in minutes |
Batch Size |
Average time for operator(minutes) |
Total average time (minutes) |
1 |
289.25 |
6 |
48.13 |
50.10 |
|
384.75 |
8 |
|
|
|
288.5 |
6 |
|
|
2 |
385 |
8 |
47.94 |
|
|
285.25 |
6 |
|
|
|
288.5 |
6 |
|
|
3 |
339.75 |
7 |
52.44 |
|
|
429.25 |
7 |
|
|
|
384.75 |
8 |
|
|
4 |
365.75 |
6 |
51.91 |
|
|
336.75 |
7 |
|
|
|
335.75 |
7 |
|
Daily Capacity = 4 / 50.10 = 0.079 per minute
Daily capacity per hour = 0.079*60
= 4.79 units per hour
Operator utilization = {(Total Working Time - Total idol time) / Total working time] * 100
= [(361.83 - 19) / 361.83] * 100
= 94.73%
2 (b)
Time in minutes |
Batch size |
Average time per unit |
289.25 |
6 |
48.21 |
384.75 |
8 |
48.09 |
288.5 |
6 |
48.08 |
385 |
8 |
48.13 |
285.25 |
6 |
47.54 |
288.5 |
6 |
48.08 |
339.75 |
7 |
48.54 |
429.25 |
7 |
61.32 |
384.75 |
8 |
48.09 |
365.75 |
6 |
60.96 |
336.75 |
7 |
48.11 |
335.75 |
7 |
47.96 |
|
|
603.12 |
Total Average time |
50.26 |
Throughput time = 50.26 minutes
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