6. Consider the following current state map for a factory which runs two 8-hour shifts per day, 250 workdays per year. The customer orders 425 units per day. a) What is the takt time for this process? (5 points) b) What is the value adding percentage of time? (5 points) c) Which station has the worst quality and what evidence exists for this? (5 points) d) Identify at least 3 locations for kaizen bursts, and what you would suggest for each (9 points) e) If the company is going to hire 2 new machine operators, where should they be assigned and why? (5 points) Annual Production Plan Market Forecast Metallservice Production Control Customer Weekly Delivery Schedule Weekly Daily Schedule Daily Weekly Schedule Daily Schedule Daily Schedule Recieving Shipping Milling Welding Painting Assembly & Inspection 5 Days 30 days 3 3 CAT-2 min C/T = 5 min CAT-7 min CAT-3 min C/O - 60 min C/O -45 min C/O 40 min C/O-35 min / Uptime = 74% Uptime -70% Uptime -55% Uptime = 95% 5 days 10 days 12 days 8 days 30 days 2 min 5 min. 7 min 2 min. 7. For the factory in the previous problem, if products are packaged 25 per container and a 20% safety stock is desired, how many kanban cards should circulate between the welding and painting workstations? (10 points) 6. Consider the following current state map for a factory which runs two 8-hour shifts per day, 250 workdays per year. The customer orders 425 units per day. a) What is the takt time for this process? (5 points) b) What is the value adding percentage of time? (5 points) c) Which station has the worst quality and what evidence exists for this? (5 points) d) Identify at least 3 locations for kaizen bursts, and what you would suggest for each (9 points) e) If the company is going to hire 2 new machine operators, where should they be assigned and why? (5 points) Annual Production Plan Market Forecast Metallservice Production Control Customer Weekly Delivery Schedule Weekly Daily Schedule Daily Weekly Schedule Daily Schedule Daily Schedule Recieving Shipping Milling Welding Painting Assembly & Inspection 5 Days 30 days 3 3 CAT-2 min C/T = 5 min CAT-7 min CAT-3 min C/O - 60 min C/O -45 min C/O 40 min C/O-35 min / Uptime = 74% Uptime -70% Uptime -55% Uptime = 95% 5 days 10 days 12 days 8 days 30 days 2 min 5 min. 7 min 2 min. 7. For the factory in the previous problem, if products are packaged 25 per container and a 20% safety stock is desired, how many kanban cards should circulate between the welding and painting workstations? (10 points)