Five Stars Manufacturing Sdn Bhd is a local company that produces portable fans. The portable fans are made up of a few components and are assembled through 4 assembly processes. A Lean Six Sigma team in Five Stars is working on a project to improve assembly process cycle time. Table 1.0 and 2.0 summarize the operation data and cycle time data collected by the Lean Six Sigma team at the projects Measure phase.

Table 1.0 Operational Data

Measures	Data
Working hour per day	8 hours
Lunch break time per day	30 minutes
Working days per month	20 days
Monthly customer order	6000 units

Table 2.0 Cycle Time Data

Assembly process	Data collected
Motor Assembly	1.6 minutes/assembly
Body Assembly	Assembled 150 parts in one hour
Blade Assembly	100 parts per hour
Packaging	1.2 minutes to complete one part

Based on the data collected by the Lean Six Sigma team, carry out the following analysis:

a) Calculate the Takt Time for the manufacturing operation.

b) Calculate the cycle time (in minutes) for the 4 assembly processes.

c) Assumed that work in progress for all assembly processes is 1 (one). Develop the Takt Time chart for assembly processes 1 to 4.

d) Based on the Takt Time Chart Developed in (c), propose the next course of action for assembly processes 1, 2, 3 and 4? Justify your proposal.

e) If the value-added time for Process 1 is 8 seconds. Calculate the Process Cycle Efficiency (PCE) for Process 1.

f) Propose improvement actions for Process 1 based on PCE calculated in (e). Justify the proposal.

g) The Lean Six Sigma team is yet to study the process from Six Sigma perspective. Propose to the team the Six Sigma target in terms of process potential index and process capability index. Explain to the team the two approaches for Six Sigma improvement.