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.

$1.$ 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$)$

$2.$ 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:

$1.$ There is an observed work$-$in$-$process $($WIP$)$ inventory of $60$ SmarTouch XL and $40$ SmarTouch PRO products before manual assembly.

$2.$ The manual assembly workstation requires nine operators and is dedicated to final assembly of both models.

$3.$ Manual assembly cycle time is $15$ minutes with a changeover time of $8$ minutes between the SmarTouch XL and SmarTouch 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$).$

Labeling Process:

$1.$ There is a WIP inventory of $30$ SmarTouch XL and $20$ SmarTouch PRO products between manual assembly and labeling.

$2.$ The labeling process is dedicated to both models and requires three operators.

$3.$ The labeling process has a cycle time of $12$ minutes, a changeover time between products of $6$ minutes to switch labels and has a reliability of $97\%.$

Packaging Process:

$1.$ There is a WIP inventory of $20$ SmarTouch XL and $10$ SmarTouch PRO products between the labeling and packaging process.

$2.$ The packaging process requires three operators.

$3.$ Packaging cycle time is $8$ minutes with a changeover time of $6$ minutes between models.

$4.$ Shipments occur twice per day $($every $12$ hours$)$ by truck.

Employees work $20$ days each month, with two $9-$hour shifts per day, including a $30-$minute lunch and three breaks of $20$ minutes each per shift. The production control office receives orders from external customers electronically. One production supervisor monitors all production processes.