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Lincoln Inc., manufactures engine assembly brackets for two major automotive customers. The manufacturing process for the brackets consists of a cell containing a forming operation,

Lincoln Inc., manufactures engine assembly brackets for two major automotive customers. The manufacturing process for the brackets consists of a cell containing a forming operation, a drilling operation, a finish grinding operation, and packaging, after which the brackets are staged for shipping, The information collected by the operations manager at Lincoln, Inc., is shown in Table 1.

Table 1 OPERATIONS DATA FOR BRACKETS AT LINCOLN, INC.

Overall Process Attributes

Average demand: 2700/day

Batch size: 50

Number of shifts per day: 2

Availability: 8 hours per shift with a 30 minute lunch break

Process Step 1

Forming

Cycle time = 11 seconds

Setup time = 3 minutes

Up time = 100%

Operators = 1

WIP = 4,000 units (Before Forming)

Process Step 2

Drilling

Cycle time = 10 seconds

Setup time = 2 minutes

Up time = 100 %

Operators = 1

WIP = 5,000 units (Before Drilling)

Process Step 3

Grinding

Cycle time = 17 seconds

Setup Time = 0 minutes

Up Time = 100%

Operators = 1

WIP = 2,000 units (Before Grinding)

Process Step 4

Packaging

Cycle time = 15 seconds

Setup time – 0 minutes

Up time = 100%

Operators = 1

WIP = 1,600 units (Before Packaging)

WIP = 15, 700 units (Before Shipping)

Customer Shipments

One shipment of 13, 500 units each week

Information Flow

All communications with customer are electronic

There is a weekly order release to Forming

All material is pushed


Using data shown in Table 1; create a current state value stream map for Lincoln, Inc., and show how the data box values are calculated.

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