QUAL$8346$ Observation Guide v$1\mathrm{.}5$

Canadian Coffee Roasters Ltd $($CCR$)$ has contacted you, a Production Specialist, requesting that you draft a value stream

map $($VSM$)$ for their facility so that they can better understand their current throughput and operational performance.

This is a brand$-$new production facility that this organization has custom built to meet the demand of a new high$-$volume

customer. Before the facility was developed, an Analyst team sat down and calculated the exact yield and machinery

needed to meet the customer$$s needs. However, after a few weeks of operation, there appears to be a discrepancy in the

required production quantity and the projected productions levels. You have been called in to verify the work of the

Analyst team and determine if they made an error in their calculations.

Unable to physically access the facility, you opted to send your trusted co$-$worker, Billy Bob, to observe and document the

process as it is completed. During Mr$.$ Bob$$s time in the facility, he decided to take a series of photos and fill$-$out his

comments directly next to the captured images to communicate the process more effectively. Unfortunately, Mr$.$ Bob

wasn$$t familiar with how to format his comments to align to the proper terminology of VSM and has instead written a

series of comments for you to distill the information from. $($The information included has not been written in a cryptic

way, the values may simply be presented in a less than desirable unit type for which you will need to translate or

standardize them$).$

On$-$site Observations:

Unit:

When processed, the coffee beans are referred to as a 'unit' of production. The exact measurement was $20$Kg of coffee

beans $($post$-$processing$)$ per unit. Therefore, each time a 'unit' is processed, exactly $20$Kg of coffee beans were processed.

Facility:

$$ Number of shifts per day: $2$

$$ Availability: $8$ hours per shift $(60-$minute time loss to breaks per shift$)$

$$ Batch Size: $220$ units

$$ Average Demand: $320$ units $/$day

$$ Weekly Demand: $1600(320$ units $/$ day $*5$ days$)$

Raw materials supplier receives a monthly sales order $($through online order form$)$ from our facility and takes $2$ days to

ship the order from the supplier to the manufacturing facility.

Process Step $1$: Hulling

Two operators are required to run the coffee bean hulling machine.

The machine can process exactly $20$ units per hour.

As the machine requires recalibration and a thorough cleaning

between usage, the resultant setup time is $25$ minutes between units.

Due to the simplistic nature of this machine, there is an observed

$100\%$ up time.

Before passing to Process Step $2$: cleaning approximately $800$ units

must be stored in inventory $($WIP$).$

$*$Hint: Normalize all time values to seconds and calculate the Per

Unit Processing Time $($Cycle Time $+$ Setup Time$).$

Process Step $2$: Cleaning

Two operators run the filtration basins. Each coffee bean unit is

added to a large filtration device that uses long paddles to spin the

hulled coffee beans, pushing debris and dust off. The unusable

materials will filter through the large mesh sifter base leaving only

cleaned beans that automatically exit the filtration basin into an

attached storage container. For the purposes of this assessment, we

will assume that $20$Kg of product is still the yield per unit. The

filtration device is rated to process $800$Kg of coffee beans per hour.

$*$Hint$,$ calculate UNITS $($how many kg per unit$)$ can be processed

each hour.

However, due to the machine becoming clogged with debris,

resulting in the necessity of frequent cleaning, the rated Up$-$Time of

this machine is only observed to be $80\%.$ Additionally, loading a unit

of beans $($Setup Time$)$ into the hopper took $12$ seconds for each unit.

Before passing to Process Step $3$: Grading $12,000$ Kg of product must

be processed. $*$Hint$,$ convert Kg to units for WIP

Process Step $3$: Grading

Each unit of coffee must next be placed through a grading device that

will test for acidity, oil consistency and flavonoids. Each unit takes

precisely $1$ minute to process with a setup time of $8$ seconds per unit.

However, as this device works on compression and heat, the

observed up$-$time is only $33\%$ and is managed $/$ tended by $1$ operator.

$8,000$Kg$$s of coffee must be graded $($WIP$)$ before we can proceed to

Process Step $4$: Roasting.

Process Step $4$: Roasting

Mr$.$ Bob requested support from the coffee roaster on how to fill out

this section. These are the values as reported by the roaster $($who just

so happened to be a former VSM Expert$).$

Cycle Time $=133$ Seconds per unit

Throughput $=60$ seconds per min$/133$ seconds per unit $=0\mathrm{.}45$ units

per minute

Setup Time $=17$ Seconds per unit

Per unit processing time $=133$ seconds $+17$ seconds $=150$ seconds

Up$-$Time $=75\%(14$ hours @ $75\%$ eff $=37,800$ seconds$)$

Operator $=1$

WIP $=400$ units

Process Step $5$: Packaging

The final step in the process is heavily automated, re