As seen from Fig. 10, 76.3% of the scrap is formed in Akana workplace. Improvements made in this workplace will substantially reduce the scrap amount. Moreover, improvements that will prevent stroke/scratch will reduce the scrap cost (it makes up 17% of scrap according to Fig. 10). 68.2% of stroke and scratches has been realized to result from the inventory building. Therefore, improvements made in inventory building system will reduce scrap rate to 11.6% ([68.2 ∗ 17]/100).
Single-shift working hours = 8 h
Number of shifts (body production line) = 2
Total working hours = 8 ∗ 60 ∗ 60 = 28,800 s ∗ 2 shifts = 57,600 s
The amount of daily demand for the body of 45cm = 450 units/day
Takt Time = Available working time/Customer demand
= 57,600/450 = 128 s.