PACT B: APPLICATION QUESTION $(40$ MARKS$)$

Answer ALL questions.

Five Stars Manufacturing Sdn Bhd is a local company that producing portable fan. The portable fans made up of few components and are assembled through $4$ assembly process. A Lean Six Sigma team in Five Stars is working on a project to improve assembly process cycle time. Table $1\mathrm{.}0$ and $2\mathrm{.}0$ summarize the operation data and cycle time data collected by the Lean Six Sigma team at the project$$s Measure phase.

Table $1\mathrm{.}0$ Operational Data

Measures Data

Working hour per day $8$ hours

Lunch break time per day $30$ minutes

Working days per month $20$ days

Monthly customer order $6000$ units

Table $2\mathrm{.}0$ Cycle Time Data

Assembly process Data collected

$1.$ Motor Assembly $1\mathrm{.}6$ minutes$/$assembly

$2.$ Body Assembly Assembled $150$ parts in one hour

$3.$ Blade Assembly $100$ parts per hour

$4.$ Packaging $1\mathrm{.}2$ minutes to complete one part

Base on the data collected by the Lean Six Sigma team, carry out the following analysis:

$($a$)$ Calculate the Takt Time for the manufacturing operation. $(5$ marks$)$

$($b$)$ Calculate the cycle time $($in minutes$)$ for the $4$ assembly processes. $(6$ marks$)$

$($c$)$ Assumed that work in progress for all assembly processes is $1($one$).$ Develop the Takt Time chart for assembly process $1$ to $4.(10$ marks$)$

$($d$)$ Bases on the Takt Time Chart Developed in $($c$),$ propose the next course of action for assembly process $1,2,3$ and $4?$ Justify your proposal. $(6$ marks$)$

$($e$)$ If the value$-$added time for Process $1$ is $8$ seconds. Calculate the Process Cycle Efficiency $($PCE$)$ for Process $1.(3$ marks$)$

$($f$)$ Propose improvement actions for Process $1$ bases on PCE calculated in $($e$).$ Justify the proposal. $(5$ marks$)$

$($g$)$ The Lean Six Sigma team is yet to study the process from Six Sigma perspective. Propose to the team the Six Sigma target in term of process potential index and process capability index. Explain to the team the two approaches for Six Sigma improvement. $(5$ marks$)$