Calculate Lead Time

Williams Optical Inc. is considering a new lean product cell. The present manufacturing approach produces a product in four separate steps. The production batch sizes are 45 units. The process time for each step is as follows:

Process Step 1	5 minutes
Process Step 2	8 minutes
Process Step 3	4 minutes
Process Step 4	3 minutes

The time required to move each batch between steps is 5 minutes. In addition, the time to move raw materials to Process Step 1 is also 5 minutes, and the time to move completed units from Process Step 4 to finished goods inventory is 5 minutes.

The new lean layout will allow the company to reduce the batch sizes from 45 units to 3 units. The time required to move each batch between steps and the inventory locations will be reduced to 2 minutes. The processing time in each step will stay the same.

Determine the value-added, non-value-added, total lead times, and the value-added ratio under the present and proposed production approaches. If required, round percentages to one decimal place.

	Present Approach		Proposed Approach
Value-added time		min		min
Non-value-added time		min		min
Total lead time		min		min
Value-added ratio (as a percent)		%		%

PLEASE ANSWER FULL QUESTION WITH FORMAT PROVIDED.

Calculate Lead Time Flint Fabricators Inc. machines metal parts for the automotive industry. Under the traditional manufacturing approach, the parts are machined through two processes: milling and finishing. Parts are produced in batch sizes of 30 parts. A part requires 5 minutes in milling and 7 minutes in finishing. The move time between the two operations for a complete batch is 5 minutes. Under the lean philosophy, the part is produced in a cell that includes both the milling and finishing operations. The operating time is unchanged; however, the batch size is reduced to 4 parts and the move time is eliminated. Determine the value-added, non-value-added, and total lead times, and the value-added ratio under the traditional and lean manufacturing methods. If required, round percentages to one decimal place. Traditional Philosophy Lean Manufacturing Philosophy 12 min 12 min Value-added time Non-value-added time 150 x min 5 X mi 365 v min 48 min Total lead time 70.6 X 100 X Value-added ratio as a percent) Feedback Check My Work Recall that lead time can be classified as one of the following: 1. Value-added lead time, which is the time spent in converting raw materials into a finished unit of product 2. Non-value-added lead time, which is the time spent while the unit of product is waiting to enter the next production process or is moved from one process to another n this for Traditional Value-added processing time EMilling time Finishing time Non-value-added time E Total within-batch wait time Move time, where Total Within-Batch Wait Time Total Time to Perform Operati (Batch Size 1) Add value-added processing time non-value-added processing time to obtain total processing time. Calculate Value-Added Ratio -Value-Added Process, Time Total Process Time In this exercise for Lean Manufacturing: Value-added processing tme E Milling time Finishing time Non-value-added time Total within-batch wait time, where Total Within-Batch Wait Time is obtained by multiplying the process time by the remaining units in the batch (waiting their turn) There is no move time Add value-added processing time non-value-added processing time to obtain total processing time. Calculate Value-Added Ratio Value-Added Process Time Total Process Time Check My Work Previous Next