In order to make a batch of Liquid Gypsum in a Gypsum factory, the following steps need to be carried out. First the correct amount of raw materials must be mixed in the proper sequence. The operator must follow specified safety instructions. After mixing, a sample is drawn and taken to a laboratory, where the sample is tested to ensure conformance to customer requirements and specifications. Next, the mixing tank is taken to a filling station and verified to be the correct one prior to filling individual cans of gypsum. The filled cans go to the packing department where labels are printed and applied to the cans. They are inspected to ensure that the labels are correct and the proper quantity was produced for the customer’s order. The cans are packed in boxes and moved to shipping.

a. Develop a flowchart that maps out this process and enrich it by adding detailed steps, which may not have been described in detail.

b. Determine if any opportunities exist for improving this process using the following questions posed in the chapter:

1. Are the steps in the process arranged in logical sequence?

2. Do all steps add value?.Can some steps be eliminated and should others be added in order to improve quality or operational performance? Can some be combined? Should some be reordered?

3. Are capacities of each step in balance; that is, do bottlenecks exist for which customers will incur excessive waiting time?