$1)$ Construct an AS$-$IS Diagram based $on$ this case study Canadian Coffee Bean Roasters $($CCBR Ltd$)$ wishes to see the full view of activities being conducted

within their new custom$-$built facility, starting with the receipt of raw materials ending with product

packaging. The process flow diagram requested by CCBR Ltd will document only the 'current state' of

activities with no improvements or modifications made to the design of the process. This document $($an

AS$-$IS diagram$)$ will serve to benchmark current performance so that CCBR Ltd can, at a future date,

implement enhancements and measure the effectiveness of future changes made against the current

performance.

On$-$site Analyst Observations:

Unit:

When processed, the coffee beans are referred to as a 'unit' of production. The exact measurement was

$20$Kg of coffee beans $($post$-$processing$)$ per unit. Therefore, each time a 'unit' is processed, exactly $20$Kg

of coffee beans were processed.

Supporting Materials

To aid your understanding of the process, note the following supporting materials:

$$ A floorplan of the facility; to help with visualization of the process execution

$$ A Product Processing Tracking $($PPT$)$ Ledger Sheet to help with comprehension of process

tracking. This ledger is a book and used to track the ins and outs of coffee beans from the

various locations within the factory.

$$ Stockroom Inventory is a online database $($CCBR$-$INV$-$SYS$)$ that records the type and quantity of

coffee beans.

$$ A Warehouse Inventory & Sales Tracking Spreadsheet to show how inventory and sales are

current tracked and managed. Data from this spreadsheet comes from the CBR$-$INV$-$SYS

database.

These files will not contain unique information required to build the process flow, the information

within is contextual to assist in understanding the conceptual nature of the narrative, functionality of

the facility and employee work.

Process observations $($In order of execution$)$:

The weekly shipment of raw coffee beans will arrive from supplier at the loading bay in the Shipping

Department $($SD$),$ where the Processing & Receiving Department $($PD$)$ will receive the order. Coffee

beans are stored in stockroom until ready for processing.

The PD worker will retrieve the pump truck and picks up the Product Processing Tracking $($PPT$)$

ledger sheet. The PD Worker will then transfer $20$ KG $($ie a skid$)$ of product onto the pump

truck and bring the units to the main temporary Storage area in PD$.$ Then pump truck is

immediately returned to its designated bay. The PD worker will update the stockroom

inventory system $($CCBR$-$INV$-$SYS$)$ to reflect the units removed.

PD worker next calibrates the Huller Machine and will step through a repetitive series of steps

wherein the PD worker will need to add $1$ unit at a time to the machine that is currently being

utilized. Here is how they add $1$ unit:

$1)$ Retrieve $1$ unit of Coffee Beans from PD Temporary Storage area.

$2)$ Add $1$ unit of Coffee Beans to the machine$$s hopper$1$

$3)$ Process unit through the machinery

$4)$ Remove the processed unit from machinery and transfer the processed

unit of coffee beans into the transfer bin.

$5)$ Record processing result$($s$)$ in Product Processing Tracking Ledger sheet$2$

$6)$ Place transfer bin in temporary storage

After the Huller Machine processes each unit in that manufacturing cell, there will be an amount of

waste produced, which the machine automatically separated from the product. This

waste must be discarded in the nearby waste bin. After all the $20$ units have been

processed, this waste bin will be emptied in the dumpster located outside the

Receiving Department loading bay.

PD worker will proceed to calibrate the Cleaning Machine. To clean the beans, the

steps are similar to the Huller machine but adding one additional step. After steps $1$

$6$ has been completed, PD worker will be required to check the Cleaning Machine for

any areas where the machine may have become clogged. If the machine is clogged,

then PD worker will utilize an automatic washer to clear out any blockages. The

cleaning cycle may take up to $10$ minutes, upon completion the worker will doublecheck to ensure that the machine has been properly cleansed. If it remains clogged, then the cleaning

cycle will repeat.

Upon completion of cleaning, a member from the Quality Control

Department $($QCD Worker$)$ will retrieve a $2-$gram sample from

each of the units$$ transfer bins. This sample will be added to the

Grading Machine, which will automatically test the coffee beans

for acidity level, roasting level and quality.

Once the Grading Machine has provided the results, a Pass$/$Fail

grade will be assigned to the corresponding coffee bean $20$Kg

unit. The $2-$gram sample is then dumped into the nearby waste

bin. This process will continue until all the units have been

tested.

Figure $1=$ Pump Truck

Figure $2-$ Calibrating the Machine

Figure $3-$ Huller Machine

After Grading, the Roasting Department will next p