Table 1: Current state data for receiving order. Activity Processing time (minutes) Waiting time (days) Customer service 30 0 Initial production scheduler: weekly 120 7 Raw material delivery 0 14 Bungee supervisor: schedule weekly 120 7 Bungee supervisor: work assignment daily 10 0 Shift leader 20 0 Total 300 28 Production Processes A description of each activity involved in the production flow is identified and discussed below: (1)Setting up the twisting process: raw material (fiber) stays in the warehouse for 1 week before being used in the twisting process. It takes about 4 minutes to move all the material from the warehouse to the processing cell. (2)Twisting process: the fiber is twisted into yarn. It takes almost 1 day to twist the fiber into yarn. (3)The packages of yarn will be used in the stranding process. (4) Braiding process: the strand is braided the day after it is made. (5)Baking, splicing, and packaging processes: after the cord is braided, it will be put in the oven, spliced, and packaged. The company selected for this case study is Superior Bungee Cords. Superior Bungee manufactures a light-weight, high-strength bungee cord that is preferred for its superior elastic qualities. The DPX yarn used in their cords provide superior abrasion and cut resistance as well as a higher coefficient of friction than similar high performance cords. The added green Hulk coating provides excellent visibility and additional abrasion resistance. Receiving Order A description of each activity involved in the information flow is identified and discussed below: (1) Receiving customer order: customer service receives an order from the customer, processes order, and passes the order information to the initial production scheduler. The processing time is approximately 30 minutes. (2)Initial production scheduling: the initial production scheduler waits 7 days to collect all orders received that week and makes a weekly production schedule and purchasing list. It takes approximately 120 minutes to process. The purchasing list is submitted to the purchasing department. The time it takes for the purchasing department to receive the purchasing list from customer service is 7 days. (3) Delivery of raw materials: once the materials are purchased, it takes 14 days for the raw materials to be delivered from the supplier. (4)Weekly production schedule: once the raw materials arrive, the rope supervisor creates the weekly production schedule. The processing time is approximately 2 hours. The raw material arriving this week will be put in process the following week (5)Shift scheduling: the rope supervisor assigns schedule to the shift supervisor. This process takes about 10 minutes. (6)Assigning process work: the shift supervisor assigns work to the twisting, stranding, braiding, and splicing processes. The estimated time to assign each process is 5 minutes. (6)Shipping: the packaged cords will be placed in a warehouse by the shipping department warehouse. The finished product stays in the warehouse about 2 days before being shipped to the customer. Table 2: Current state data for production processes Department Processing time (hrs) 0 19.6 5.5 6.3 36 1.3 Waiting time and NVA time (hrs) 168 26.81 26.12 2.02 0.25 0.83 AWWNW Material handling time (mins) 4 3 2 3.5 3 4.5 Warehouse Twisting Stranding Braiding Oven Splicing and packaging Shipping Total VA time Material Handling time Production lead time Receiving order: shipping 0 0 48 69 hours 20 minutes 8 days 36 days Create a process map and then a value stream map for Superior Bungee's receiving and production processes. Discuss the value added and non-value added times and steps. Then identify some areas for improvement (you do not need to quantify these, but you do need to justify them). The company selected for this case study is Superior Bungee Cords. Superior Bungee manufactures a light-weight, high-strength bungee cord that is preferred for its superior elastic qualities. The DPX yarn used in their cords provide superior abrasion and cut resistance as well as a higher coefficient of friction than similar high performance cords. The added green Hulk coating provides excellent visibility and additional abrasion resistance. Receiving Order A description of each activity involved in the information flow is identified and discussed below: (1)Receiving customer order: customer service receives an order from the customer, processes order, and passes the order information to the initial production scheduler. The processing time is approximately 30 minutes. (2)Initial production scheduling: the initial production scheduler waits 7 days to collect all orders received that week and makes a weekly production schedule and purchasing list. It takes approximately 120 minutes to process. The purchasing list is submitted to the purchasing department. The time it takes for the purchasing department to receive the purchasing list from customer service is 7 days. (3)Delivery of raw materials: once the materials are purchased, it takes 14 days for the raw materials to be delivered from the supplier. (4)Weekly production schedule: once the raw materials arrive, the rope supervisor creates the weekly production schedule. The processing time is approximately 2 hours. The raw material arriving this week will be put in process the following week (5)Shift scheduling: the rope supervisor assigns schedule to the shift supervisor. This process takes about 10 minutes. (6)Assigning process work: the shift supervisor assigns work to the twisting, stranding, braiding, and splicing processes. The estimated time to assign each process is 5 minutes. Table 1: Current state data for receiving order. Activity Processing time (minutes) Waiting time (days) Customer service 30 0 120 7 Initial production scheduler: weekly Raw material delivery Bungee supervisor: schedule weekly 0 14 120 7 Bungee supervisor: work assignment daily 10 0 Shift leader 20 0 Total 300 28 Production Processes A description of each activity involved in the production flow is identified and Miscussed below: (1)Setting up the twisting process: raw material (fiber) stays in the warehouse for 1 week before being used in the twisting process. It takes about 4 minutes to move all the material from the warehouse to the processing cell. (2)Twisting process: the fiber is twisted into yarn. It takes almost 1 day to twist the fiber into yarn. (3)The packages of yarn will be used in the stranding process. (4) Braiding process: the strand is braided the day after it is made. (5)Baking, splicing, and packaging processes: after the cord is braided, it will be put in the oven, spliced, and packaged. (6)Shipping: the packaged cords will be placed in a warehouse by the shipping department warehouse. The finished product stays in the warehouse about 2 days before being shipped to the customer. Table 2: Current state data for production processes Department Processing time (hrs) 0 19.6 5.5 6.3 36 1.3 Waiting time and NVA time (hrs) 168 26.81 26.12 2.02 0.25 0.83 Material handling time (mins) 4 3 2 3.5 3 4.5 Warehouse Twisting Stranding Braiding Oven Splicing and packaging Shipping Total VA time Material Handling time Production lead time Receiving order: shipping 0 0 48 69 hours 20 minutes N 8 days 36 days Create a process map and then a value stream map for Superior Bungee's receiving and production processes. Discuss the value added and non-value added times and steps. Then identify some areas for improvement (you do not need to quantify these, but you do need to justify them). Table 1: Current state data for receiving order. Activity Processing time (minutes) Waiting time (days) Customer service 30 0 Initial production scheduler: weekly 120 7 Raw material delivery 0 14 Bungee supervisor: schedule weekly 120 7 Bungee supervisor: work assignment daily 10 0 Shift leader 20 0 Total 300 28 Production Processes A description of each activity involved in the production flow is identified and discussed below: (1)Setting up the twisting process: raw material (fiber) stays in the warehouse for 1 week before being used in the twisting process. It takes about 4 minutes to move all the material from the warehouse to the processing cell. (2)Twisting process: the fiber is twisted into yarn. It takes almost 1 day to twist the fiber into yarn. (3)The packages of yarn will be used in the stranding process. (4) Braiding process: the strand is braided the day after it is made. (5)Baking, splicing, and packaging processes: after the cord is braided, it will be put in the oven, spliced, and packaged. The company selected for this case study is Superior Bungee Cords. Superior Bungee manufactures a light-weight, high-strength bungee cord that is preferred for its superior elastic qualities. The DPX yarn used in their cords provide superior abrasion and cut resistance as well as a higher coefficient of friction than similar high performance cords. The added green Hulk coating provides excellent visibility and additional abrasion resistance. Receiving Order A description of each activity involved in the information flow is identified and discussed below: (1) Receiving customer order: customer service receives an order from the customer, processes order, and passes the order information to the initial production scheduler. The processing time is approximately 30 minutes. (2)Initial production scheduling: the initial production scheduler waits 7 days to collect all orders received that week and makes a weekly production schedule and purchasing list. It takes approximately 120 minutes to process. The purchasing list is submitted to the purchasing department. The time it takes for the purchasing department to receive the purchasing list from customer service is 7 days. (3) Delivery of raw materials: once the materials are purchased, it takes 14 days for the raw materials to be delivered from the supplier. (4)Weekly production schedule: once the raw materials arrive, the rope supervisor creates the weekly production schedule. The processing time is approximately 2 hours. The raw material arriving this week will be put in process the following week (5)Shift scheduling: the rope supervisor assigns schedule to the shift supervisor. This process takes about 10 minutes. (6)Assigning process work: the shift supervisor assigns work to the twisting, stranding, braiding, and splicing processes. The estimated time to assign each process is 5 minutes. (6)Shipping: the packaged cords will be placed in a warehouse by the shipping department warehouse. The finished product stays in the warehouse about 2 days before being shipped to the customer. Table 2: Current state data for production processes Department Processing time (hrs) 0 19.6 5.5 6.3 36 1.3 Waiting time and NVA time (hrs) 168 26.81 26.12 2.02 0.25 0.83 AWWNW Material handling time (mins) 4 3 2 3.5 3 4.5 Warehouse Twisting Stranding Braiding Oven Splicing and packaging Shipping Total VA time Material Handling time Production lead time Receiving order: shipping 0 0 48 69 hours 20 minutes 8 days 36 days Create a process map and then a value stream map for Superior Bungee's receiving and production processes. Discuss the value added and non-value added times and steps. Then identify some areas for improvement (you do not need to quantify these, but you do need to justify them). The company selected for this case study is Superior Bungee Cords. Superior Bungee manufactures a light-weight, high-strength bungee cord that is preferred for its superior elastic qualities. The DPX yarn used in their cords provide superior abrasion and cut resistance as well as a higher coefficient of friction than similar high performance cords. The added green Hulk coating provides excellent visibility and additional abrasion resistance. Receiving Order A description of each activity involved in the information flow is identified and discussed below: (1)Receiving customer order: customer service receives an order from the customer, processes order, and passes the order information to the initial production scheduler. The processing time is approximately 30 minutes. (2)Initial production scheduling: the initial production scheduler waits 7 days to collect all orders received that week and makes a weekly production schedule and purchasing list. It takes approximately 120 minutes to process. The purchasing list is submitted to the purchasing department. The time it takes for the purchasing department to receive the purchasing list from customer service is 7 days. (3)Delivery of raw materials: once the materials are purchased, it takes 14 days for the raw materials to be delivered from the supplier. (4)Weekly production schedule: once the raw materials arrive, the rope supervisor creates the weekly production schedule. The processing time is approximately 2 hours. The raw material arriving this week will be put in process the following week (5)Shift scheduling: the rope supervisor assigns schedule to the shift supervisor. This process takes about 10 minutes. (6)Assigning process work: the shift supervisor assigns work to the twisting, stranding, braiding, and splicing processes. The estimated time to assign each process is 5 minutes. Table 1: Current state data for receiving order. Activity Processing time (minutes) Waiting time (days) Customer service 30 0 120 7 Initial production scheduler: weekly Raw material delivery Bungee supervisor: schedule weekly 0 14 120 7 Bungee supervisor: work assignment daily 10 0 Shift leader 20 0 Total 300 28 Production Processes A description of each activity involved in the production flow is identified and Miscussed below: (1)Setting up the twisting process: raw material (fiber) stays in the warehouse for 1 week before being used in the twisting process. It takes about 4 minutes to move all the material from the warehouse to the processing cell. (2)Twisting process: the fiber is twisted into yarn. It takes almost 1 day to twist the fiber into yarn. (3)The packages of yarn will be used in the stranding process. (4) Braiding process: the strand is braided the day after it is made. (5)Baking, splicing, and packaging processes: after the cord is braided, it will be put in the oven, spliced, and packaged. (6)Shipping: the packaged cords will be placed in a warehouse by the shipping department warehouse. The finished product stays in the warehouse about 2 days before being shipped to the customer. Table 2: Current state data for production processes Department Processing time (hrs) 0 19.6 5.5 6.3 36 1.3 Waiting time and NVA time (hrs) 168 26.81 26.12 2.02 0.25 0.83 Material handling time (mins) 4 3 2 3.5 3 4.5 Warehouse Twisting Stranding Braiding Oven Splicing and packaging Shipping Total VA time Material Handling time Production lead time Receiving order: shipping 0 0 48 69 hours 20 minutes N 8 days 36 days Create a process map and then a value stream map for Superior Bungee's receiving and production processes. Discuss the value added and non-value added times and steps. Then identify some areas for improvement (you do not need to quantify these, but you do need to justify them)