Can you please explain how you find (1) cycle time, (2) flow time, and (3) How many cars are you likely to encounter at any given time as work-in-process inventory? If you could explain the calculations that would be very helpful!

Stamping: In the stamping process, coils of aluminum are unwound, cut into level pieces of sheet metal, and then inserted into stamping presses that shape the metal according to the geometry of the Model S. The presses can shape a sheet of metal in roughly 6 seconds.

Subassembly: The various pieces of metal are put together using a combination of joining techniques, including welding and adhesion. This creates the body of the vehicle.

Paint: The body of the vehicle is then moved to the paint shop. After painting is completed, the body moves through a 350 oven to cure the paint, followed by a sanding operation that ensures a clean surface.

General assembly: After painting, the vehicle body is moved to the final assembly area. Here, assembly workers and assembly robots insert the various subassemblies, such as the wiring, the dash board, the power train and the motor, the battery pack, and the seats.

Quality testing: Before being shipped to the customer, the now-assembled car is tested for its quality. It is driven on a rolling road, a test station that is basically a treadmill for cars that mimics driving on real streets.

Overall, the process is equipped with 160 robots and 3000 employees. The process produces some 500 vehicles each week. It takes a car about 35 days to move from the beginning of the process to the end. The Plant works two-shifts of 8 hours per day, and it is open 5 days per week.