Metcalf, Inc., manufactures engine assembly brackets for two major automotive customers. The manufacturing process for the brackets consists of a cell containing a forming operation, a drilling operation, a finish grinding operation, and packaging, after which the brackets are staged for shipping. The information collected by the operations manager at Metcalf, Inc., is shown in Table 4.4.

a. Using data shown in Table 4.4, create a current value stream map for Metcalf, Inc., and show how the data box values are calculated.
b. What is the takt time for this value stream?
c. What is the production lead time at each process in the value stream?
d. What is the total processing time of this value stream?
e. What is the capacity of this value stream?

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Overall Process Attributes Process Step 1 Process Step 2 Process Step 3 Process Step 4 Average demand: 2,700/day Batch size: 50 Number of shifts per day: 2 Availability: 8 hours per shift with a 30-minute lunch break Forming Drilling Grinding Packaging Cycle time = 11 seconds Setup time 3 minutes Uptime = 100% Operators = 1 WIP = 4,000 units (Before Forming) Cycle time=10 seconds Setup time = 2 minutes Uptime = 100% Operators = 1 WIP = 5,000 units (Before Drilling) Cycle time 17 seconds Setup time=0 minutes Uptime = 100% Operators 1 WIP = 2,000 units (Before Grinding) Cycle time 15 seconds Setup time 0 minutes Uptime = 100% Operators = 1 WIP 1,600 units (Before Packaging) WIP = 15,700 units (Before Shipping)