Question: Product Total demand/6 months Month information Hours worked Allowable breaks Machine efficiency 1 13000 10 days for this product Two 8 hour shifts One 30

Product	Total demand/6 months	Month information	Hours worked	Allowable breaks	Machine efficiency
1	13000	10 days for this product	Two 8 hour shifts	One 30 min paid break per shift	91%

Product Total demand/6 months Month information

The factory has 4 production lines for producing three types of components.

Line 1: Stainless Steel Sheet Metal Components

Line 2: Fabrication of Main Frame items with Stainless steel angles and Plates

Line 3. Steel Casting, machining and fabrication other accessories

Line 4 is basically assembly line for assembling the products 1,2, and 3

Complete a Value Stream MAP showing the following information

a) Compute Takt time

b) Prepare Current State Value Stream Map

c) Show Time line for current state map,

d) Inventory Triangles and Inventory in Time scale in the time lines,

e) Analyze Current State Metrics (Total Lead time, Total Value added time, Overall Scrap rate, %, Overall Manpower; %VAT)

f) Prepare kaizen step-based improvement plan Map

g) Future State map with Time line, inventory triangles, Total Lead time, Value added time, and analysis of metrics

Operation 1 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 2 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 3 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 4 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 1 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 2 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 3 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Assembly 1 Operator Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Assembly 2 Operator Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Assembly 3 Operator Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 1 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 2 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 3 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 4 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 1 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 2 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 3 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 4 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 1 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 2 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 3 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Assembly 1 Operator Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Assembly 2 Operator Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Assembly 3 Operator Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 1 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 2 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 3 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %: Operation 4 Operator 1 Cycle time (C/T): Changeover Time: (CO) Inventor (INV) Input Side (INS): Output Side (OUS) Scrap Rate %

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