(a) Using suitable examples, discuss the importance of schedule stability in lear systems. 10 marks b) Beaufort is a leather goods manufacturer based in London, offering the full-scale production of high-quality custom products. The company in interested in using the data collected during value stream mapping to evaluate the current performance of its production capacity. Collected data are reported in Table 1. The company has estimated a Takt time of 19 seconds/unit. Table 1: Data collected during a value stream mapping exercise Average demand: 2700/day Overall Number of shifts per day: 2 Process Attributes Availability: 8 hours per shift with a 30-minute lunch break Process Step Cycle time = 300 seconds A Setup time = 60 minutes Up time = 90% Operators = 2 WIP = 1,783 units (Before pre-treatment) Process Step Cycle time = 45 seconds B Setup time = 10 minutes Up time = 90% Operators = 2 WIP = 1202 units (Before Powder coater) Process Step Cycle time = 300 seconds C Setup time = 240 minutes Up time = 100% Operators = 2 WIP = 733 units (Before Welding) WIP = 593 units (Before Shipping) Customer One shipment each month Shipments Information All communications with supplier and customer are Flow electronic There is a manually weekly order release to process A All material is pushed i) Using a suitable example, explain the purpose of the Value Stream Mapping (2 marks) ii) Using the data reported in Table 1, draw the corresponding value stream mapping (5 marks) iii) Use the value stream mapping from ii) to determine the total production lead time, total processing time for manufacturing the wallet. (2 marks) iv) Use the value stream mapping from ii) to calculate the per unit processing time for Process A if the company decides to run a batch size of 360 units. With the same batch size, identify the bottleneck process. (2 marks) v) If the batch size is 300 units, calculate the per unit processing time for Process C. for the same batch size, calculate the capacity of process A. (2 marks) vi) Use the value stream mapping to determine the batch size necessary to restrict overall process capacity to 10 units per hour. (2 marks) (a) Using suitable examples, discuss the importance of schedule stability in lear systems. 10 marks b) Beaufort is a leather goods manufacturer based in London, offering the full-scale production of high-quality custom products. The company in interested in using the data collected during value stream mapping to evaluate the current performance of its production capacity. Collected data are reported in Table 1. The company has estimated a Takt time of 19 seconds/unit. Table 1: Data collected during a value stream mapping exercise Average demand: 2700/day Overall Number of shifts per day: 2 Process Attributes Availability: 8 hours per shift with a 30-minute lunch break Process Step Cycle time = 300 seconds A Setup time = 60 minutes Up time = 90% Operators = 2 WIP = 1,783 units (Before pre-treatment) Process Step Cycle time = 45 seconds B Setup time = 10 minutes Up time = 90% Operators = 2 WIP = 1202 units (Before Powder coater) Process Step Cycle time = 300 seconds C Setup time = 240 minutes Up time = 100% Operators = 2 WIP = 733 units (Before Welding) WIP = 593 units (Before Shipping) Customer One shipment each month Shipments Information All communications with supplier and customer are Flow electronic There is a manually weekly order release to process A All material is pushed i) Using a suitable example, explain the purpose of the Value Stream Mapping (2 marks) ii) Using the data reported in Table 1, draw the corresponding value stream mapping (5 marks) iii) Use the value stream mapping from ii) to determine the total production lead time, total processing time for manufacturing the wallet. (2 marks) iv) Use the value stream mapping from ii) to calculate the per unit processing time for Process A if the company decides to run a batch size of 360 units. With the same batch size, identify the bottleneck process. (2 marks) v) If the batch size is 300 units, calculate the per unit processing time for Process C. for the same batch size, calculate the capacity of process A. (2 marks) vi) Use the value stream mapping to determine the batch size necessary to restrict overall process capacity to 10 units per hour. (2 marks)