Consider the data given in the TWI example and particularly the “Welding+Deflash” continuous flow cell developed after the lean implementation. Assume that the 10 sec operator cycle times on Welding and Deflash machines are composed of 5 seconds of loading, 4 seconds of unloading 1 second of start time (to push the start button) - Level-2 automation. Also assume that, in the current layout it takes 4 seconds for the operators to walk between any two machines and the machine changeover time is 2.5 minutes.

a) Calculate the Operator C/T and effective machine C/T and plot their balance charts. What is the cycle time of this cell? Does your equipment meet the takt and does this cell meet the takt? Explain how TWI will manage to meet the daily demand with this cycle time and what potential problems this will cause. Can you recommend any solutions?

 b) Following the questions in the second book to design an improved “Welding + Deflash” continuous flow cell, and also draw the layout of your proposed solution. Assume that the footprint of each machine is 4-feet (width) x 3-feet (depth). In your proposed solution you can assume that level-3 automation is possible. Calculate the Operator C/T and effective machine C/T and plot their balance charts. What is the cycle time of this cell? Does your equipment meet the takt and does this cell meet the takt? Explain how TWI will manage to meet the daily demand with this cycle time and what potential problems this will cause. Can you recommend any solutions?

c) Comment on any improvements you have achieved in part (b) compared to current state in part (a). What kind of analysis would be needed to decide whether level-3 automation is worthwhile to implement or not? Discuss pros and cons of implementing level-3 automation to help the management decide.

d) During the implementation in part (b) you realize that there is actually 2 seconds of walking time between any two machines, does this impact your solution above in part (b)?