Question 1.

It is the case of a USA based export-oriented Gym Machine Manufacturer company. They manufacture 3 types of Exercise Machines. Exercise Machine EXM 101; EXM 102, and EXM 103. They export the machines through three agents mainly to EUROPE and a small % to AUSTRALIA. For easy understanding consider following:

Products	Total Demand /per quarter (3 months)	Month Information	Hours worked	Allowable breaks	Machine efficiency
EXM101	11,500	6.0 days allocated for this product	Two 8-hour shift /day	30 minutes paid lunch break in each shift	90%
EXM102	14,000	9 days allocated	Two 8-hour shift/day	One 30 minutes paid meal break/shift	90%
EXM 103	18,000	12 days allocated	Two 8-hour shift/day	One 30 minutes paid meal break/shift	90%

The factory has 4 production lines for producing three types of components.

Production Line 1: Stainless Steel Sheet Metal Components; Line 2: Fabrication of Main Frame items with Stainless steel angles and Plates; Line 3. Steel Casting, machining, and fabrication other accessories; Line 4 is basically assembly line for assembling the products 1,2, and 3

1. Compute takt time (3 points).
2. Prepare current state value stream map (5 points),
3. Show timeline (5 points) for current state map,
4. Inventory triangles and inventory in time scale (4 points) in the timelines
5. Analyze current state metrics ( total lead time, total value-added time, overall scrap rate, scrap %, overall manpower; %VAT) (4 points)
6. Prepare kaizen step-based improvement plan map (9 points)
7. Future state map with timeline, inventory triangles, total lead time, value added time, and analysis of metrics - 10 points per item =Total Points (50 points)