Bergabunge Management 83 NRII Process Name Cell + door assembly Required labor 1 1 Cycle time (sec.) 95 Changeover time (min.) 0 . Up-time 100% % Observed inventory 3 days Process Name Required labor Cycle time (sec.) Changeover time (min.) Up-time Observed inventory Accessory insertion 1 32 0 95% 2 days (K111 Finy[ Two 15-min break periods, All the processes stop during these break periods. Production control department The department is required to perform the following actions(by fax or printed form): Receives a monthly forecast from the buyer and enters it into the SAP system. Receives weekly order from the buyer, Sends the 8-week forecast to the raw material 8- supplier, Replenishes the raw sheets by a monthly order, Generates the MRP-based weekly requirements, Sends weekly operations schedules to all the departments. Question 1): Study the problem carefully and then you need to draw the future state map based on the current situation. Show all your work Process Name Engine + condenser insertion Required labor 2 Cycle time (sec.) 85 Changeover time (min.) 0 Up-time 100% Observed inventory 3 days Process Name Required labor Cycle time (sec.) Changeover time (min.) Up-time Observed inventory Packing 1 1 65 0 100% 4 Production processes: The production line consists of the following processes. All the processes occur in the following order and each part should visit all of the stations. For security reasons, gas insertion is done at a separate station which operates in 3 shifts. Parts are shipped and received daily to/from this station Process Name Case description: AB Company for producing refrigerators is in the process of implementing the lean concepts. As a major step to convert its traditional production system to a lean one is to develop the current state map. The company produces different models of refrigerators but they decided to start with only one product family that contains two models: model 1501 and model 3001. The final products are sent directly to the buyer XY once a week while the sheets, raw materials, are received from the vendor MN one time every two weeks. Buver's demand 7200 units per month (4000 units of type 1 501 and 3200 units of type 3001) The pallet can hold up to 4 refrigerators. The buyer receives one weekly shipment from the company Work time 20 day per month One 8-hr shift per day, Overtime is allowed, Process Name Sheets bending and cutting Required labor 3 Cycle time (sec.) 25 Changeover time (min.) 30 Up-time 60% Observed inventory 8 days of raw sheets 2 days of cut sheets Required labor Cycle time (sec.) Changeover time (min.) Up-time Working time Observed inventory Gas insertion (Has to go to a special station) 1 265 5 90% 3 shifts 5 days Process Name Required labor Cycle time (sec.) Changcover time (min.) Up-time Observed inventory Base assembly 1 30 0 95% 4 days Process Name Required labor Cycle time (sec.) Changeover time (min.) Up-time Observed inventory Final assembly 2 96 0 100% 2 days Process Name Required labor Cycle time (sec.) Changeover time (min.) Up-time Observed inventory Insulation foaming 1 1 60 25 85% 2 days Process Name Testing Required labor 1 1 Cycle time (sec.) 40 Changeover time (min.) 5 Up-time 90% Observed inventory 2 days