You manage the Spartan Hot Cakes Company. Your product, a pound cake, is very popular. Recently high demand for this product has put your production process under pressure, and it is not performing well. You decide to try Lean Production methods. You gathered the following information about the process:

Orders come in from your customers via email weekly. Currently demand is 300 cakes per day. You distribute schedules to the production process daily via paper production schedules. You ship to your customer once per day.

You send orders weekly to your supplier via email. The supplier ships materials (eggs, milk, flour, sugar, vanilla, butter, baking powder, salt) to you Mondays and Wednesdays.

Raw materials from your supplier go into your warehouse. To simplify this Kaizen event, we are going to focus on only the eggs and focus on the remaining raw materials in a future Kaizen event.

The raw materials go from the warehouse refrigerator into the Wet Mixing department, and the eggs are mixed with the milk and vanilla. That mixture goes to the Complete Mixing department where the other ingredients are added and mixed. From there it goes to the Panning department, and then the Baking department. Once the cakes leave the Baking department, they go into the Inspection station. Once inspected, the cakes go to Packaging and then to Shipping.

You have measured the cycle time, change over time and up time of each of the processes, and found:

Wet Mixing: Cycle Time 140 sec.; Change Over Time 360 sec.; Up Time 99%

Complete Mixing: Cycle Time 220 sec.; Change Over Time 360 sec.; Up Time 98%

Panning: Cycle Time 30 sec.; Change Over Time 0 sec.; Up Time 100%

Baking: Cycle Time 35 min.; Change Over Time 600 sec.; Up Time 82%

Inspection: Cycle Time 20 sec.; Change Over Time 0 sec.; Up Time 100%

Packaging: Cycle Time 10 sec.; Change Over Time 0 sec.; Up Time 91%

You operate weekdays, one shift of ten hours per day.

You measure the WIP between the work stations. There are 3,000 eggs in Raw Material Storage. The count after each station is: the equivalent of 900 cakes after Wet Mixing, 250 cakes after Complete Mixing, 200 cakes after Panning, 30 cakes after Baking, 0 cakes after Inspection, and 450 cakes after Packaging.

You measure the yield of each work station. The yield measures are:

Wet Mixing: 94%

Complete Mixing: 94%

Panning: 100%

Baking: 88%

Inspection: 93%

Packaging: 100%

Assignment Note: Show your work and have units on your numbers.

Briefly discuss what you learned in the videos and readings. Where they of value? (10%)

Draw a Value Stream Map (25%)

Calculate the lead time, value adding time, and the percent value adding time. (10%)

Calculate takt time. (5%)

Draw a Future State Map. (20%)

Itemize the improvements you make for your future state. (20%)

Estimate what the lead time, value adding time, and percent value adding time would be after you make the improvements. (10%)