TABLE OF CONTENTS The Emca kanban implementation team needs to refer back to the value stream map and supporting data to extract the information needed to determine the actual capacity of the head machining resources. This information includes:
The number of machines available for production,
The number of shifts they operate on,
The calculation of gross machine capacity,
Machine reliability,
A calculation of net machine capacity,
Cycle time data,
Set-up data.
The following head machining equipment analysis summarizes the above information for the machining centers.
| HEAD MACHINING EQUIPMENT ANALYSIS | |||||||
|---|---|---|---|---|---|---|---|
| Capacity per Shift (sec.) | Number of Shifts | Gross Machine Capacity (sec.) | Actual Capacity | Net Machining Capacity (sec.) | Set-Up Time (min.) | Set-Up Time (sec.) | |
| Machine Center 1 | 27000 | 2 | 54000 | 60% | 32400 | 15 | 900 |
| Machine Center 2 | 27000 | 2 | 54000 | 70% | 37800 | 30 | 1800 |
| Total Net Machining Capacity: | 70200 |
The team determined that Emca has 54,000 seconds of gross available capacity at each machine center. As the total demand for both machine centers on the Requirements Study Worksheet (50,525) did not exceed 108,000 (54,000 2 machines) seconds, Emca has sufficient gross capacity. However, the team needs to look at this more carefully and understand the net (true) capacity and the impact of waste in the machining processes. The team will accomplish this by performing a process called Order Frequency Determination.
Order frequency is the frequency at which Emca plans to set up and order each golf club head. Determining the order frequency is a four-step process.
