2 (40 points) The following Value Stream Map (VSM) represents the current situation of a company that wants to adopt lean principles. The VSM is generated after a period of observation during which cycle times (CT) are measured. The main processes are Drying, Molding, Assembly, Testing Packing and Shipping. Around these are the inventory triangles with the associated inventory levels (this may be a snapshot or may include a statistical distribution). In the VSM below, some parts are empty on purpose since you will select the related parameters and make necessary computations. Assume that the company works 3 shiftsday, 8 hours shift with a one-hour lunch break in a shift. Paris Drying 30 | CO CIT CO Ambey CIT SO WE CO Tev OT L. OD Nm 100% CT 40 W CR mie Uptime 1994 90% (Before solving the question, fill in the following table by selecting integer values from the given intervals and copy only the 1" & 4 columns into your answer sheet) Y Parameter Definition of parameter Interval Value B Batch size [500; 1,000) X Inventory level for plastics, in days [ (before Drying) [10:20) WIP inventory level, in pieces [1.000; 10,000 (before Molding) 2 WIP inventory level, in pieces [1.000; 10,000) (before Packing) Cycle time (CIT) for Molding [10; 1001 in seconds) Cycle time (CT) for Testing [10; 100) 2 (in seconds) Changeover time (CO) [5:20) M for Molding (in minutes) N Changeover time (CIO) [5:20) for Testing in minut) Assuming that the selected parameters are valid for the VSM above, answer the following questions: (Always use 2-scientific digits for non-integer times (such as seconds, minutes, hours) & Always round the quantities expressed in units to the nearest integer.) a) (10 points) Compute the daily capacity of the system (in pieces). b) (10 points) For feasibility, the daily capacity should be greater than or equal to the daily demand (assembled units per day). Suppose that the daily demand corresponds to 95% of daily capacity. Compute the daily demand. Compute the corresponding takt time (minutes per piece). c) points) Compute the total production lead time in days). d) points) Compute total processing time in seconds e) 2 points) Compute the value-added time in seconds) f) (2 points) Compute the non-value-added time (waste) (in days) g) (10 points) Currently, the WIP inventory level before Drying is.xdays. Suppose that we want to reduce the total production lead time found in parte) by 10%, as an opportunity for improvement. Compute the desired improved production lead time (in days). What should be the new WIP inventory level before Drying (in days) to achieve this improvement, assuming that Y, Z WIP inventory level before Assembly, WIP inventory level before Testing, WIP inventory level before Shipping and the daily demand stay the same! 2 (40 points) The following Value Stream Map (VSM) represents the current situation of a company that wants to adopt lean principles. The VSM is generated after a period of observation during which cycle times (CT) are measured. The main processes are Drying, Molding, Assembly, Testing Packing and Shipping. Around these are the inventory triangles with the associated inventory levels (this may be a snapshot or may include a statistical distribution). In the VSM below, some parts are empty on purpose since you will select the related parameters and make necessary computations. Assume that the company works 3 shiftsday, 8 hours shift with a one-hour lunch break in a shift. Paris Drying 30 | CO CIT CO Ambey CIT SO WE CO Tev OT L. OD Nm 100% CT 40 W CR mie Uptime 1994 90% (Before solving the question, fill in the following table by selecting integer values from the given intervals and copy only the 1" & 4 columns into your answer sheet) Y Parameter Definition of parameter Interval Value B Batch size [500; 1,000) X Inventory level for plastics, in days [ (before Drying) [10:20) WIP inventory level, in pieces [1.000; 10,000 (before Molding) 2 WIP inventory level, in pieces [1.000; 10,000) (before Packing) Cycle time (CIT) for Molding [10; 1001 in seconds) Cycle time (CT) for Testing [10; 100) 2 (in seconds) Changeover time (CO) [5:20) M for Molding (in minutes) N Changeover time (CIO) [5:20) for Testing in minut) Assuming that the selected parameters are valid for the VSM above, answer the following questions: (Always use 2-scientific digits for non-integer times (such as seconds, minutes, hours) & Always round the quantities expressed in units to the nearest integer.) a) (10 points) Compute the daily capacity of the system (in pieces). b) (10 points) For feasibility, the daily capacity should be greater than or equal to the daily demand (assembled units per day). Suppose that the daily demand corresponds to 95% of daily capacity. Compute the daily demand. Compute the corresponding takt time (minutes per piece). c) points) Compute the total production lead time in days). d) points) Compute total processing time in seconds e) 2 points) Compute the value-added time in seconds) f) (2 points) Compute the non-value-added time (waste) (in days) g) (10 points) Currently, the WIP inventory level before Drying is.xdays. Suppose that we want to reduce the total production lead time found in parte) by 10%, as an opportunity for improvement. Compute the desired improved production lead time (in days). What should be the new WIP inventory level before Drying (in days) to achieve this improvement, assuming that Y, Z WIP inventory level before Assembly, WIP inventory level before Testing, WIP inventory level before Shipping and the daily demand stay the same