INDU $321$Lean ManufacturingASSIGNMENT $1$Due back on February $13,20241$:$00$ PM$.$ This is an individual assignment. Submitonly your own work. Your submitted workwill be carefully checked for plagiarism.Problem description:LGG company is interested in implementing leanconcepts in its refrigerator production facility toreduce its production lead time and costs. A majorstep to convert its traditional production system toa lean one is to develop the current state map. Thecompany produces different models ofrefrigerators, but they decided to start with aproduct family that contains two models: model$301$ and model $302.$ The final products are sentdirectly to the distributor Sellers Inc. once a weekand the metal sheets are received from theirsupplier Steels Co$.$ once a week.Customers demandWhile the weekly demand may exhibitconsiderable mix variations, the total demand hasbeen quite stable at an average of $140$ units perweek $($with an average of $100$ units for model $301$and $40$ units for model $302).$ Sellers Inc. currentlyreceives one weekly shipment from the companyand would prefer daily shipments in the future aswell as some reduction in unit cost.Work time$5$ days per week; One $8-$hr shift per day.Two $15-$min paid break periods;The regular time labour cost is $$40/$hr and theovertime labour cost is $$60/$hr$.$The current collective agreement limits overtimeto a maximum of $2$ hrs per day.Production Control DepartmentThe Production Control Department performs thefollowing actions:Receives a monthly forecast from the buyer viafax and enters it manually into the SAP system.Receives weekly order from the buyer via fax,Sends the $8-$week forecast to the raw materialsupplier via fax,Replenishes the raw metal sheets by weeklyorders via fax,Generates the MRP$-$ based weekly requirements,Sends weekly operations schedules to all thedepartments.Production processes:Each unit goes through all the production processesin the following order.Process Name Metal cutting &bending $($shared$)$Used labor $1$Cycle time $($sec$.)45$Changeover time$($min$.)45$Up$-$time $60\%$Observed inventory $15$ days of raw sheets$($worth $$6000),380$ units of cut$/$bentsheets @$$5$ each$*$Process Name Base & DoorassemblyUsed labor $3$Cycle time $($min$)36($cannot reduce$)$Changeover time $($min$.)2$Up$-$time $95\%$Observed inventory $300($units$)$ @ $$50$each$*$Process Name InsulationUsed labor $2$Cycle time $($min$)20($cannot reduced$)$Changeover time $($min$.)5$Up$-$time $85\%$Observed inventory $261($units$)$ @ $$60$each$*$Process Name Engine $+$Condenser$2/2$Used labor $2$Total cycle time $($min$)20($cannot reduce$)$Changeover time $($min$.)4$Up$-$time $95\%$Observed inventory $210($units$)$ @ $$150$each$*$Process Name Gas insertion$*$Used labor $1$Cycle time $($min$)15$Changeover time $($min$.)15$Up$-$time $90\%$Observed inventory $200($units$)$ @ $$300$each$**$Gas insertion is done at another location andcannot be relocated. Refrigerators are transferredto the gas insertion station once a day.Process Name Main AssemblyUsed labor $6$Total cycle time $($min$)60$Changeover time $($min$.)0$Up$-$time $95\%$Observed inventory $247($units$)$ @ $$500$each$*$Process Name Testing &PackagingUsed labor $3$Cycle time $($min$)27$Changeover time $($min$.)5$Up$-$time $90\%$Observed inventory $290($units$)$ @ $$650$each$*$Process Name Shipping$*$ Note: Given costs represent the unit material$+$ labour cost of an item at that particular stageof production $($excluding overhead cost$).$Annual unit holding cost is historically shown tobe $15\%$ of the material $+$ labour costs.Use Microsoft Visio to draw the current statemap $($CSM$)$ of the case described below. Writea report to explain the material and informationflow.Also show your calculations for the totalproduction lead$-$time and value$-$added time aswell as all the information required in thefollowing table:CSMTotal Production Leadtime$($days$)$Total Value Added Time$($minutes$)$Number of OperatorsTotal annual Mtl$+$Labour CostUnit labour costUnit holding cost $($annual$)$Your report should also contain a discussion ofthe wastes you see and their sources.Submit the following two files on Moodle: $1)$MS Word file with all our detailed answers tothe questions above, and $2)$ your MS Visio filefor your value stream map. Submit your filesin their original format. Do not submit pdf$,$ zip,or tar files.Moodle will close at $1$:$00$PM and late assignmentswill not be accepted.Process Name Accessory insertionUsed labor $2$Cycle time $($min$)16$Changeover time $($min$.)0$Up$-$time $95\%$Observed inventory $200($units$)$ @ $$600$each$*$