Process Flow Design Exercise - Online version The goal of this exercise is to apply the concepts learnt in the course to a practical process design and management problem. Your task is to develop a process flow design and management plan for ramping up the production of an innovative light-flashing circuit board module. The engineering department has provided the design specifications for three light-flashing module variations. You must determine how to produce these three variations to meet the customer demand. PRODUCT: There are three different models of the product (Economy, Deluxe, and Imperial). Each product consists of a breadboard (with a pre-mounted IC chip), a few wire strips, and other electronic components. The product specifications are given in the appendix (see Appendix F). Ahsolutely no deviations are permitted from these specifications including the exact position of the components on the breadboard. The customer using these products is extremely quality conscious, requiring that no defective units will be accepted and that the module be aesthetically pleasing GOAL: Your team's objective is to design a production system to maximize net cash flow, where Net Cash Flow - Revenue - Material Cost - Labor Cost The cash inflows consist of the revenue generated by products that are sold to the customer. The cash outflows consist of the cost of materials purchased and labor costs. See Appendix A for cost and revenue data. Demand: There will be demand for 54 units to be produced and delivered in 40 minutes. A sequence for delivery of the units will be specified by the customer using the form in Appendix C. The demand for these units will be in the ratio of 4:4:2 (4 Economy, 4 Deluxe, 2 Imperial). A very important condition in the customer contract mentions that the customer will accept finished goods only in the sequence specified by the customer. Acceptance of a unit by the customer hence depends on three conditions: (1) all preceding orders have been met. (2) the unit functions properly. (3) There are no quality problems (e.g., hanging or exposed wire, no deviations from specifications). You will be responsible to deliver finished units to your customer. Units rejected by customer will be returned to you. Process Design. Layout and Execution: Please answer the process related questions below. Q1 (Process design): Determine number of workstations, tasks assigned to different workstations, and the number of workers assigned to different stations. (A workstation could perform a task or a group of tasks.) Then, draw a process flow diagram. Show tasks and stations, storage points, and number of workers assigned to different stations. The total number of workers used in manufacturing, both direct and indirect, cannot exceed 8. Provide necessary calculations to support your answer. [1 to 2 pages) For ease of presentation, you can give your workers any names (even funny names or real names) or simply call them Worker I, Worker 2, etc. You can use the estimated times for production tasks in the table below. There is some variability and the numbers below are mean times. Task Cut wire Splice wird Mount wire Mount capacitor Mount LED Mount resistors Mount buzzer Expected Time 28 seconds for 4 84 seconds for 4 40 seconds for 4 10 seconds 13 seconds 40 seconds for 3 8 seconds The estimated time to test a unit with a battery tester is about 13 seconds. Note that, you may need to include labor time for tasks such as purchasing and order delivery Q2-a (Process Layout): You are allowed to use at most 3 rectangular tables (each 30" x 6"). You can arrange the tables any way you want. Show the layout of tables and location of workers. Clearly show storage location of inventories, Justify. El page] 2-6 (Process execution plan): Provide a brief description of your management system. Be certain to identify whether your system is "pull" or "push". Determine what information is needed for decision making for all the different operations' tasks. Show important information flows. (You can draw information flows on the process flow diagram and or on the layout.) Your proposal should include a plan for purchase (for example, do you plan to make a single large purchase or multiple small purchases), a plan for delivery, and a plan for dealing with defective units. For delivery, assume that the customer table is 3 feet from you and that it is your responsibility to deliver units to the customer. Your worker will need to walk to the customer table. Customer will inspect cach and every unit including wire lengths. Any defective units will be returned to you. For purchase, you can assume that the supplier table is about 10 feet from you and your worker will need to walk to the supplier to purchase items. [1 to 2 pages] Planning for production risk factors: Your team will not carry out the production but needs to plan for various risk factors during production (for example, customer rejecting a unit because the wire is too long, or the green bulb lighting up continuously hut does not flash, or defective components, or the unit working properly when you shipped to customer but customer found it to be defective, etc.). The production interval is 40 minutes long. In this interval, your team will: () receive the order sheet with 54 orders marked on it, (m) engage in productive work (anship finished units to customer, (iv) collect any rejected units from the customer, and (v) purchase materials. Note that the customer will inspect and accept orders in the sequence specified in the order sheet. The rejected units belong to you. Parts once purchased cannot be returned. However, any defective parts can be replaced. Q3: What is the estimated profit for your team. Show your calculations. [12 page] Q4: Identify key concepts from the course that you have used in your design. Explain. [1 to 2 pages] Q5: Explain how your team's plan addresses the risk factors such as above and any other problems you can think of. [1 to 2 pages] 2 Appendix F: Unit Types Economy: yellow LED (Note: LED should light up continuously) Deluxe: Green LED (Note: LED should FLASH, and not light up continuously) Imperial: Red LED (Note: LED should light up continuously and the buzzer should sound continuously) Note on Wires Each product requires 4 wires: Three short and one long Short Wire: Length