Batch sizing using fixed batch coverage
In this case, an example is easier to explain the calculation mode for a fixed batch coverage.
If you daily operating time is 20 hours and the % allocated to change over is 10%:
In order to produce homogeneous batch coverage, we have consider the sum of the Change over time of all KANBAN references and evaluate how many time this sum is contained in the Time Allocated for Change Overs for a day.
The daily time allocated for change overs is: 20 x 60 x 0.10 = 120 minutes
We have 4 references:
| Reference | Daily demand in quantity | Change over time (COT) in minutes | Cycle time (CT) in seconds |
| A | 300 | 4 | 5 |
| B | 1800 | 10 | 10 |
| C | 300 | 16 | 10 |
| D | 400 | 10 | 7 |
The sum of all change over times is: 4 + 10 + 16 + 10 = 40 minutes
It is possible to change over: 120 / 40 = 3 times per the day for each reference.
Then, for each reference, we divide the daily demand by this value: it is the batch size of the reference in quantity.
Batch size for each reference:
- Reference A: 300 / 3 = 100
- Reference B: 1800 / 3 = 600
- Reference C: 300 / 3 = 100
- Reference D: 400 / 3 = 133
Obviously, the batch time will be different for each reference:
- Reference A: 100 x 18 = 1800 seconds = 30 minutes
- Reference B: 600 x 9 = 5400 seconds = 90 minutes
- Reference C: 100 x 36 = 3600 seconds = 60 minutes
- Reference D: 133 x 27 =3591 seconds = 60 minutes
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