Calculate Lead Time 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 66 units. The process time for each step is as follows: Process Step 1 7 minutes Process Step 2 5 minutes Process Step 3 9 minutes Process Step 4 4 minutes The time required to move each batch between steps is 16 minutes. In addition, the time to move raw materials to Process Step 1 is also 16 minutes, and the time to move completed units from Process Step 4 to finished goods inventory is 16 minutes. The new lean layout will allow the company to reduce the batch sizes from 66 units to 4 units. The time required to move each batch between steps and the inventory locations will be reduced to 3 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 % Feedback In this exercise for Present: Value-added processing time = Add together Process steps 1-4 Non-value-added time = Total within-batch wait time + Move time, where Total Within-Batch Wait Time = (Total Time to Perform Operations) x (Batch Size - 1). Add value-added processing time + non-value-added processing time to obtain total processing time. Calculate Value-Added Ratio = Value-Added Process Time ÷ Total Process Time In this exercise for Proposed: Value-added processing time = Add together Process steps 1-4 Non-value-added time = Total within-batch wait time + Move time, where Total Within-Batch Wait Time is obtained by multiplying the process time by the remaining units in the batch (waiting their turn) Add value-added processing time + non-value-added processing time to obtain total processing time. Calculate Value-Added Ratio = Value-Added Process Time ÷ Total Process Time
Calculate Lead Time
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 66 units. The process time for each step is as follows:
| Process Step 1 | 7 | minutes |
| Process Step 2 | 5 | minutes |
| Process Step 3 | 9 | minutes |
| Process Step 4 | 4 | minutes |
The time required to move each batch between steps is 16 minutes. In addition, the time to move raw materials to Process Step 1 is also 16 minutes, and the time to move completed units from Process Step 4 to finished goods inventory is 16 minutes.
The new lean layout will allow the company to reduce the batch sizes from 66 units to 4 units. The time required to move each batch between steps and the inventory locations will be reduced to 3 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 | % |
In this exercise for Present:
Value-added processing time = Add together Process steps 1-4
Non-value-added time = Total within-batch wait time + Move time, where Total Within-Batch Wait Time = (Total Time to Perform Operations) x (Batch Size - 1).
Add value-added processing time + non-value-added processing time to obtain total processing time.
Calculate Value-Added Ratio = Value-Added Process Time ÷ Total Process Time
In this exercise for Proposed:
Value-added processing time = Add together Process steps 1-4
Non-value-added time = Total within-batch wait time + Move time, where Total Within-Batch Wait Time is obtained by multiplying the process time by the remaining units in the batch (waiting their turn)
Add value-added processing time + non-value-added processing time to obtain total processing time.
Calculate Value-Added Ratio = Value-Added Process Time ÷ Total Process Time
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