Question 3 (6 marks):

Company produces inner wheel housing at its plant. The maximum forecasted demand for the part is 50000 a month. The company operates 27 days in a month and the net operating time per day is 1320 min. The production process of the wheel is as follows:

Data:

Drawing: CT = 2.5 sec, Up time = 100%, 1 operator

Trimming and piercing: CT = 2.4 sec, Up time = 100%, 1 operator

Trimming and Cam piercing: CT = 2.6 Sec, Uptime= 100%, 1 operator

Restrike and parting: CT = 2.2 sec, Uptime = 100%, 1 operator

Quality check-up 1: CT = 38 sec, 1 operator

Welding: CT = 56 sec, Uptime = 100%, 1 operator

Quality Check-up 2: CT = 21 sec, Uptime = 100%

Supplier generally supplies raw material to the plant once every week.

The plant generally holds 20000 units of raw material at its warehouse located inside the plant. It also holds a bank of 1850 parts between Quality check-up 1 and Welding process. It also holds finished goods inventory 10000 units

The plant also holds inventory between other processes:

Drawing Trimming & Piercing = 20 units

Trimming & piercing Trimming & Cam piercing = 20 units

Trimming & Cam piercing Restrike & parting = 50 units

Restrike & parting Quality check 1 = 10 units

Almost no inventory is held between welding and Quality check-up 2

Customer always sends an annual forecast followed by monthly and daily requirements to PC department. The plant in turn sends weekly and daily requirement to its supplier. The raw material and finished goods are transported by truck. The company generally pushes the material to the downstream process.

Using the above data:

a) Create a current state value stream map.

b) What is the ratio of the value added time to the total production lead time?

c) What kind of wastes would you suggest to reduce or eliminate? (at least 3)