Question
Williams Optical Inc. is considering a new lean product cell. The present manufacturing approach produces a product in four separate steps. The production batch sizes
Williams Optical Inc. is considering a new lean product cell. The present manufacturing approach produces a product in four separate steps. The production batch sizes are 79 units. The process time for each step is as follows:
Process Step 1 | 9 | minutes |
Process Step 2 | 8 | minutes |
Process Step 3 | 5 | minutes |
Process Step 4 | 4 | minutes |
The time required to move each batch between steps is 13 minutes. In addition, the time to move raw materials to Process Step 1 is also 13 minutes, and the time to move completed units from Process Step 4 to finished goods inventory is 13 minutes.
The new lean layout will allow the company to reduce the batch sizes from 79 units to 5 units. The time required to move each batch between steps and the inventory locations will be reduced to 2 minutes. The processing time in each step will stay the same.
Determine the value-added, non-value-added, and total lead times, and the value-added ratio under the present and proposed production approaches. If required, round percentages to one decimal place.
Present Approach | Proposed Approach | |||
Value-added time | fill in the blank 1 | min | fill in the blank 2 | min |
Non-value-added time | fill in the blank 3 | min | fill in the blank 4 | min |
Total lead time | fill in the blank 5 | min | fill in the blank 6 | min |
Value-added ratio (as a percent) | fill in the blank 7 | % | fill in the blank 8 | % |
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