Tombro Industries is in the process of automating one of its plants and developing a flexible manufacturing system. The company is finding it necessary to make many changes in operating procedures. Progress has been slow, particularly in trying to develop new performance measures for the factory. In an effort to evaluate performance and determine where improvements can be made, management has gathered the following data relating to activities over the last four months: Month 2 3 4 1 Quality control measures: Number of defects 190 140 120 90 Number of warranty claims Number of customer complaints 54 36 25 11 100 120 110 130 Material control measures: 10 days 3.3% 7 days 3.0% 5 days 3.2% 3 days 2.7% Purchase order lead time Scrap as a percent of total cost Machine performance measures: Machine downtime as a percentage of availability Use as a percentage of availability Setup time (hours) Delivery performance measures: Throughput time Manufacturing cycle efficiency (MCE) Delivery cycle time Percentage of on-time deliveries 78% 81% 79% 82% 74% 76% 69% 70% 2.3 2.3 2.3 2.3 ? ? ? ? ? ? ? ? 84% 87% 91% 95% The president has read in industry journals that throughput time, MCE, and delivery cycle time are important measures of performance, but no one is sure how they are computed. You have been asked to assist the company, and you have gathered the following data relating to these measures: Average per Month (in days) 1 4 Wait time per order before start of production Inspection time per unit Process time per unit Queue time per unit Move time per unit 16.9 14.8 12.1 9.0 0.3 0.2 0.6 0.6 0.7 0.7 0.7 0.7 5.6 1.4 5.7 1.3 5.6 1.3 5.7 1.4 Required: 1-a. Compute the throughput time for each month. (Round your answers to 1 decimal place.) Throughput Time Month 1 days Month 2 days Month 3 days Month 4 days 1-b. Compute the manufacturing cycle efficiency (MCE) for each month. (Round your answers to 1 decimal place (i.e., 0.123 should be entered as 12.3).) Manufacturing cycle efficiency ( Month 1 % Month 2 Month 3 % Month 4 1-c. Compute the delivery cycle time for each month. (Round your answers to 1 decimal place.) Delivery cycle time days days Month 1 Month 2 Month 3 days days Month 4 3-a. Refer to the inspection time, process time, and so forth, given for month 4. Assume that in month 5 the inspection time, process time, and so forth, are the same as for month 4, except that the company is able to completely eliminate the queue time during production using Lean Production. Compute the new throughput time and MCE. (Round your Throughput Time to 1 decimal place. Round your MCE percentage answer to 1 decimal place (i.e., 0.123 should be entered as 12.3).) Month 5 Throughput time days Manufacturing cycle efficiency (MCE) 3-b. Refer to the move time, process time, and so forth, given for month 4. Assume that in month 6 the inspection time, process time, and so forth, are the same as in month 4, except that the company is able to eliminate both the queue time during production and the inspection time using Lean Production. Compute the new throughput time and MCE. (Round your Throughput Time to 1 deci place. entered as 12.3).) decimal place (i.e., 0.123 should be percentage answer your Month 6 |days Throughput time Manufacturing cycle efficiency (MCE) %
