assignment-1-lean-six-sigma
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School
Conestoga College *
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Course
8010
Subject
Industrial Engineering
Date
Dec 6, 2023
Type
Pages
6
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Assignment 1 - Lean six sigma
Topics in Quality Engineering (Conestoga College)
Studocu is not sponsored or endorsed by any college or university
Assignment 1 - Lean six sigma
Topics in Quality Engineering (Conestoga College)
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Assignment 1
:
Determining the Value Stream Map, Takt Time, and
Total Capacity
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Queston
: - MegaAuto, Inc. manufacturers engine assembly brackets for two
major automotve customers. The manufacturing process for the brackets consists
of a cell containing a forming operaton, a drilling operaton, a fnish grinding
operaton, and packaging, afer which the brackets are staged for shipping. The
informaton collected by the operatons manager at MegaAuto, Inc. is shown
below.
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a. Using data shown above; create a value stream map for MegaAuto, Inc. and
show how the data box values are calculated.
Answer
Assumptons:-
Weekly Schedule is manually delivered to Forming, Drilling, Grinding,
Packaging and Shipping.
There is one Supplier.
Raw material is supplied weekly.
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b. What is the takt tme for this manufacturing cell?
The takt tme is the rate of producton of units in a cell to match the demand of
customers.
Daily Demand of the customer = 2700 brackets per day
Daily Availability= (7.5 hours) × (2 shifs per day) × (3600 seconds per hour) =54,000 seconds per day
Takt tme = Daily Availability/ Daily Demand= (54,000 seconds per day)/ 2700 brackets per day
=20 seconds per piece.
c. What is the producton lead tme at each process in the manufacturing cell?
Total Producton lead tme is equal to the total inventory held in all processing
steps divided by daily demand.
Semi-fnished material lead tme = (4000/2700) =1.48 days
WIP lead tme between Forming and Drilling Processes = (5000/2700) = 1.85 days
WIP lead tme between Drilling and Grinding Processes = (2000/2700) =0.74 day
WIP lead tme between Grinding and Packaging = (1600/2700) = 0.59 day
WIP lead tme between Packaging and Shipping = (15700/2700) = 5.81 days
Total Producton
Lead Time
= (1.48+1.85+0.74+0.59+5.81) = 10.47 days (almost 10
days)
d. What is the total processing tme of this manufacturing cell?
The total processing tme is submission of cycle tme of each process in
manufacturing cell.
Total Processing Time of this manufacturing cell = (11+10+17+15) =53 seconds
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e. What is the capacity of this manufacturing cell?
Capacity of this manufacturing is the maximum output of company to produce
brackets and it is calculated by fnding botleneck positon.
Capacity = Availability/Time at botleneck
Capacity
at
Forming
Capacity
at
Drilling
Capacity
at
Grinding
Capacity
at
Packaging
Cycle Time =11 Seconds
Cycle Time = 10 Seconds
Cycle Time = 17 Seconds
Cycle Time = 15 Seconds
Set up Time = ( 3 Minutes ×
60 Seconds per Minute)/50
Units per batch =
3.6
Seconds
Set up Time = ( 2 Minutes
×
60
Seconds
per
Minute)/50 Units per
batch =
2.4 Seconds
Set up Time = 0
Set up Time = 0
Per Unit Process Time =
(11+3.6) =
14.6 Seconds
Per Unit Process Time =
(10+2.4) =
12.4 Seconds
Per Unit Process Time =
(17+0) =
17 Seconds
Per Unit Process Time =
(15+0) =
15 Seconds
Batch size of 50 units,
In this manufacturing cell, the Grinding process is the botleneck.
Availability at Grinding = 54,000 seconds per day
Time at botleneck = 17 seconds
Capacity
(Availability/Time at botleneck) = 54,000/17 = 3176 units per day
The capacity of this manufacturing cell (3176 Units per day) is greater than the
Daily Demand (2700 Units per day).
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