Page 184 - The Toyota Way Fieldbook

160 THE TOYOTA WAY FIELDBOOK

Part Name Quantity per 8 hours Ratio
A 200 4
B 100 2
C 50 1
D 50 1
Total 400

Table 7-4. Quantity of Parts as a Relative Ratio

TIP
Set Your Pitch Based on Current Conditions
Unless you are well along in your lean journey, you will not likely
set a one-hour pitch initially. We recommend progressing in halves.
If you currently move material at a daily pitch (or it is not defined),
start with a shift-by-shift pitch. Then incrementally reduce the
pitch by one-half as the processes become more capable and
refined.

the standardization of work for material handlers, including routes that are
completed during the pitch time or a multiple of the pitch. Material quantities
are standardized, and the quantities per container may be adjusted to match the
requirement per pitch. For illustrative purposes we assume that this process is
capable of advanced heijunka and produces each item in the exact sequence,
and that the total available work time is eight hours. Demand is 400 total pieces,
and the ratios are shown in Table 7-4.
Based on the quantity required and the ratios, the repeating heijunka pat-
tern (which minimizes batching) would be: ABACABAD—ABACABAD—
ABACABAD
The pitch time to repeat the pattern is determined by dividing eight hours
by the demand of 400 pieces and multiplying by the number of pieces in a pat-
tern (pitch):
28,800 seconds (eight hours) per day / 400 pieces 72 seconds per piece
And:
72 seconds per piece x 8 pieces per pitch
576 seconds per pitch (9 minutes 36 seconds) or 6.25 pitch-cycles per hour.