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JIT/Lean: (50 points) JIT/Lean: Production Smoothing (heijunka), Kanban, and misc. issues:

(17 points) Toyota Georgetown (a.k.a. Toyota Motor Manufacturing, Kentucky or simply TMMK) has two mixed-model production lines each producing over two eight-hour shifts per day (with 480 minutes of working time per shift per production line), for five days per week. The models produced at TMMK include Camry (C) and Avalon (A). Suppose, in the recent past, the weekly demand rates for Camry and Avalon models are 5700 C and 450 A, respectively. If the same mixed-model JIT scheduling (and TAKT time) is used in both production lines, calculate the TAKT time, in seconds, of the assembly line. How many units of each model will be produced before the production cycle is repeated? For one such production cycle, determine a satisfactory JIT production sequence of models.(12 points) Suppose there are two types of Camrys, CG and CH, representing gas-engine only and hybrid, respectively. Similarly, there are two types of Avalons, AG and AH. Out of every 19 Camrys made at TMMK, 3 are hybrids, the rest are gas-engine. Similarly, out of every 6 Avalons made at TMMK, one is a hybrid. How does the presence of the Camry and Avalon gas-engine only and hybrid models affect the above JIT production sequences? [Specify the JIT production sequence for a typical production line, assuming they both operate with similar TAKT times and production sequences.](6 points) Why are a relatively constant volume and stable mix essential to kanban & TPS?(15 points) Consider the Hybrid Battery. Suppose the same Battery Pack is used in the Avalon Hybrid as in the Camry Hybrid. Estimate the TAKT time of the line that produces Battery Packs for the Camry and Avalon Hybrid models. Now consider component X of the battery pack, called an NiMH battery module. There is one production line that makes battery modules that go into Battery Packs with a similar schedule to vehicle assembly (two eight-hour shifts per day for 5 days/week). Suppose each battery pack consists of 34 battery modules; i.e., each Battery Pack is made from 34 units of the X component. The average lead-time (= wait time in queue + production time) for one container of Component X is one week. The kanban container size for X is 345 units (battery modules); so each time Component X’s kanban authorizes production 345 units of X are produced. A 15% minimum safety stock is desired to compensate for uncertainties; this means that the desired target inventory is at least 1.15 times the work-in-process inventory level computed using only the average data provided above (without uncertainties). Estimate the number of kanban cards required for Component X.

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