Instructor's Guide

Model: Variation in Pull System-Manufacturing

File: 6-2 Variation in a Pull System-Manufacturing.cfg

Video: 6-2 Variation in a Pull System-Manufacturing

Motif: Manufacturing

Concepts Simulated: Variation, Pull System, Kanban

Related Models: 1-2 Push vs Pull with Kanban-Mfg.cfg

4-2 Variation in a Push System-Mfg-Part 1

TrainingView1-NoVariation

In this model, we use a kanban system similar to what was introduced in “1-2 Push
vs Pull with Kanban-Mfg.cfg”. It is best to view that model before this one. In this
model, no defective parts are produced.

Parts go from the first (green) work station to a second (blue) work station. The first
work station produces 1.75 parts per second, they take 10 seconds on a conveyor,
then take 2 seconds per part at the second work station.

The system is controlled by 7 kanbans. Whenever 7 parts are being produced at the
green work station, on the conveyor, in the blue queue or being processed at the
blue work station, the green work station will stop producing.

© 2015 The Big Lean Simulation Library, LLC

Run the model. Notice in the screen shot below that one kanban is at the blue work
station and 5 are at the conveyor. So green is free to use the 7th kanban and is
producing the part (Production Status color is green).

Run the model until it stops. Note how many parts were produced in the chart.

© 2015 The Big Lean Simulation Library, LLC

View: TrainingView2-VariationAdded

This view shows what happens when randomness is added. Now the first station
produces parts uniformly between .75 and 2.75 seconds and the second station
processes the uniformly 1 to 3 seconds per part. The the averages are the same,
except now there isvariation.

Run the model again. Notice the parts are no longer equally spaced on the conveyor.
It could happen that blue may be starved momentarily, at which time it is not
processing at all! (See “4-2 Variation in a Push System-Mfg-Part 1”)

Notice this system produced fewer parts than the system with no variation.

If we increased the number of kanbans, the blue workstation would never be starved
and it would produce as many as the first system. But if we do that, we now have
the disadvantages associated with a larger queue and work-in-process (as shown in
“1-2 Push vs Pull with Kanban-Mfg.cfg”.

© 2015 The Big Lean Simulation Library, LLC