Please note: values of N and X are given based on Group # below: :

1. (Points 45) A bolt manufacturing factory ships N number of bolts per X days a week. There are 15 process steps described below to realize the bolt and ship to customer: Assume the Factory does not have any breaks during the day.
   1. N=2700, X=7 days
      1. Consider Only one shift production in a day with no breaks.
2. Step 1: Blanking, CT: 0.75 Sec, CO: 6 hours, 1 operator; MC reliability 100%, scrap rate 0.05%

Step 2: Necking, CT: 8.57 Sec, CO: 1.5 hours, 1operator; MC reliability 100%, scrap rate 0.05%

Step 3: shape Head, CT: 10 Sec, CO: 0.5 hours, 1operator; MC reliability 100%, scrap rate 0.05%

Step 4: Pickle and Dubois, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0%

Step 5: Carburize and induction, CT: 2.7 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 1%

Step 6: Receiving, CT: 0.01 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05%

Step 7: Metrology Lab, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05%

Step 8: Roll thread, CT: 0.857 Sec, CO: 2 hours, 1operator; MC reliability 100%, scrap 0%

Step 9: Phosphorous and Oil, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0%

Step 10: Re-Roll and Box, CT: 0.857 Sec, CO: 2 hours, 1operator; MC reliability 100%, scrap 0%

Step 11: 100% sort, CT: 5 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05%

Step 12: Salt Spray, CT: 0.02 Sec, CO: 10 hours, 1operator; MC reliability 100%, scrap 0.05%

Step 13: Doc final, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05%

Step 14: Chemical and physical certification, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05%

Step 15: Label & ship, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05%

Inventory information:

Before:

Step1 500 coils, equivalent to 5 days bolts requirements;

Step2 38,400 pieces;

Step3 3360 pieces;

Step4 2880; pieces;

Step5 4500 pieces;

Step6 1066 pieces;

Step7 6000 pieces;

Step8 4500 pieces;

Step9 1243 pieces;

Step10 1243 pieces;

Step11 1450 pieces;

Step12 7500pieces;

Step13 4500pieces;

Step14 4500pieces;

Step15 3000pieces; and at the shipment store just after step 15: 7500 pieces

Rubric

1. Compute takt time 2 points
2. Prepare current state value Stream map including time line and information flow 9 points,
3. Now show the inventory lead time in number of days by your computation: 4 points
4. Plan improvement in a copy of current state map (improvement planning Map using kaizen lightening sparks) 10 points
5. Prepare the future state based on your Groups effort showing all required information for a value stream - 15 points