Part $2(20$ points$)$

SmarTouch produces two product models: SmarTouch XL and SmarTouch PRO. The processes for manufacturing these products are identical $($i$.$e$.,$ one value stream$).$ SmarTouch receives $12,000$ total orders for products per year from external customers. Annual demand for the SmarTouch XL is $9,000$ units. The Final Assembly Department receives parts from the Main Assembly Department. Final Assembly utilizes three processes: manual assembly, labeling, and packaging.

Create a current state value stream map for the process flow described below. Include the inventory lead times and the process cycle times for all processes using units of minutes.

$(14$ points$)$

Indicate the a$)$ overall takt time in minutes, b$)$ total process time in minutes, and c$)$ total production lead time in minutes for this value stream $($neglect changeover$).$

$(6$ points$)$

Information about the three processes in the Final Assembly Department is detailed below.

Manual Assembly Process:

There is an observed work$-$in$-$process $($WIP$)$ inventory of $60$ SmarTouch XL and $40$ SmarTouch PRO products before manual assembly.

The manual assembly workstation requires nine operators and is dedicated to final assembly of both models.

Manual assembly cycle time is $15$ minutes with a changeover time of $8$ minutes between the SmarTouch XL and SmatTouch PRO, and an overall reliability of $99\%$ for SmarTouch XL and $98\%$ for SmarTouch PRO $($i$.$e$.,1\%$ and $2\%$ of products do not pass inspection, respectively, and must be sent for rework$).$