Question
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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