Case Study 2
Group sections:
Ibraheem Hoseni
Abdullah Bensalama
Alia Abbas
1) How does the andon process work and what are its fundamental aspects? How much does it greet to ruin the line? What are the benefits of stopping the line?
a. The andon cord is a cord running adjacent to assembly lines that enables workers to stop employment if they detect a defect; this procedure dramatizes manufacturing problems and acts as a pressure for process improvements. In other words in TPS, the next step is the customer; hence every mental imagery should only let the flow units move downstream later it has been inspected and evaluated as good parts. Of course, in the case, there is a color and red lines where it indicates where is the andon cord should be casted (70% of the line) . a team member whos behind in finishing his task on the assembly line pulls the andon cord to attract the team leader, the andon pull turns on a flashing light and triggered loud symphony and lights up the work station having the problem.
b. Depending on the stoppage time, the cost varies as all other resources in the upstream and downstream become somehow idle.
* From the case study, we got the following information
Number of team up Leaders = 204
Work stations = 353
Number of team members = 769
Team leader salary (5%-8% Premium) = 17.
85$/HR and 18.36$/HR
Team member requital = 17$/HR
Overtime will cost an extra 50% for each member.
Shift Duration = 525-(15 paid break X2)-45 = 450 min
aggregate produced cars per shift = 474 cars with a 60 sec start up.
catamenia production rate is 95% = 474 X 0.95 = 450 cars per shift
* As give above, the cost calculation for the scenario when production fell (from the case study) from 95% to 85% is as follows:
* 474 cars X 0.85 = 403 Cars
* Hence the number of cars produced = 450 403 = 47 cars
* As a result, we need 43 minutes of extra time to finish the defected cars
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