Demand

The company works on two shifts, each of eight hours, with a $30$ minutes break for

shift.

The production family B is made by a range of $6$ different products, from B$1$ toB$6$

$($products with high volume$/$ sold everyday$).$

The total demand of the production family A is on average $1800$ units per day.

Twice per day products are delivered to the customers.

Processes

The company has $5$ production stages $+$ shipping department. Press and cutter are parallel

stages. Afterwards component coming from press and cutter are welded together $($welding

stage$).$ Then there is drilling and finishing stages.

The press and cutter are shared resources with other production families. The press is

dedicated to this production family for $60\%$ of its time. The cutter for $70\%$ of its time. All

other resources are instead fully dedicated to this family.

The press and cutter are technologically advanced machines, others are quite simple manual

machines. The press works $6$ different types of product for the concerned production family.

The cutter produces $6$ different types of components, one for each of the six finished products

offered by the company. On each piece $($metal foil$)$ of the press must be welded two identical

cut components $($pipes$).$

One operator conducts each production stage.

The raw material supplier delivery weekly metal sheets that feed the press and pipes that the

cutting needs. There are $13$ days of supply for raw material: respectively $13$ days of metal foil

in front of the press and $13$ days of pipes in front of the cutter.

Cycle times and changeover time are very similar for all product.

Information flow

Customers make a forecast $($to $30/60/90$ days$)$ and send it monthly to the

Production Planning department $($PP$).$

Customers issues orders to Sales daily, with expected delivery date on the

following day..

PP tracks in the system the orders received from Sales and develops a weekly

production plan for each production process and a daily scheduling plan for

deliveries to Shipment.

PP sends a forecast $(30/60$ days$)$ to the supplier and confirms orders weekly.

a$.$ Create a Value Stream Map for the current state $($Provide all necessary data in VSMas

learned in the class$)$ and calculate the following:

iv$)$ Lead Time

v$)$ Value Added Time

vi$)$ Process Cycle Efficiency

b$.$ Based on the gap between customer demand and actual daily throughput:

Use $5$W$1$H$,$ Cause and Effect Diagram and $5$ why analysis to identify the root cause

of throughput loss. $($Start with the problem statement as: "Missing customer demand

due to throughput loss"$).$

c$.$ Once Lean tool applied to identify the loss, provide recommendation to make overall

improvement and draw future State VSM