Q$1.$

Draw the current state map for the Value Steam.

eltham electromagnetics Ltd produces electromagnetic components and

assemblies. One particular line produces assembled microwave emitters for

microwave ovens manufacturer Rapidheat PLC$.$

Production Processes

The manufacturing line process involves pressing, folding, assembly, testing

and packaging.

The finished assemblies are staged and shipped to the customer each day.

$25$ coils of stainless$-$steel sheet are delivered by the supplier, $2$ times each

month.

Rapidheat$$s Requirements

$2000$ components per day. Of which:

$1200$ are for $240$V microwave ovens $($European range$)$

$800$ are for $120$V microwave ovens $($American range$)$

Emitters are to be shipped on trays of $50$ units per tray.

The customer orders in multiples of trays.

One daily shipment is sent to the customer by truck.

Rapidheat work $3$ shifts per day, $20$ working days per month.

Work Time

$20$ working days per month

$2$ shifts of $8$ hours per day, one $(1)/(2)$ hour meal break, and two $12\mathrm{.}5$ minute

coffee breaks per shift.

Production Control Department

MRP system

Customer emails demand forecast each week for the next $90$ days

Send monthly order for raw materials to supplier by fax

Customer emails daily firm order

Issues weekly schedule to pressing, folding, assembly, testing and

packaging.

Issues daily shipping schedule to despatch.

Process Information

The processes occur in the following sequence and each workpiece passes

through all the processes.

$1.$ Pressing

Cycle Time $=1$ second, producing $10$ components per cycle

Change Over Time $=25$ minutes

Inventory in front of the process $=15$ days of raw material

Uptime $=90\%$

$1$ Operator

$2.$ Folding

Cycle Time $=22$ seconds

Change Over Time $=15$ minutes

Inventory in front of the process $=4800$ European, $3200$ American

Uptime $=85\%$

$1$ Operator

$3.$ Assembly

Cycle Time $=56$ seconds

Change Over Time $=10$ minutes

Inventory in front of the process $=6000$ European, $4000$ American

Uptime $=100\%$

$2$ Operators

$4.$ Testing

Cycle Time $=35$ seconds

Changeover Time $=12$ minutes

Inventory in front of process $=1800$ European, $1200$ American

Uptime $=100\%$

$1$ Operator

$5.$ Packaging

Cycle Time $=2$ minutes per tray

Changeover Time $=30$ seconds

Inventory in front of process $=3600$ European, $2400$ American

Uptime $=100\%$

$1$ Operator

$6.$ Shipping

One shipment per day, typically of $40$ trays

Inventory before shipping $=240$ trays of European assemblies, $160$ trays of

American assemblies