QUAL8340 Assignment 3 - Observation Guide v1.2 A geographically remote gourmet coffee bean manufacturer has contacted you, a Production Specialist, requesting that you draft a value stream map (VSM) for their facility so that they can better understand their current throughput and operational performance. This is a brand-new production facility that this organization has custom built to meet the demand of a new high-volume customer, before the facility was developed, an internal Analyst team sat down and calculated the exact yield and machinery needed to meet the customers needs. However, after a month of operation there appears to be a discrepancy in the required production quantity and the projected productions levels. You have been called in to verify the work of the Analyst team and determine if they made an error in their calculations. Unable to physically access the facility, you opted to send your trusted co-worker, Billy Bob, to observe and document the process as it is completed. During Mr. Bobs time in the facility, he decided to take a series of photos and fill-out his comments directly next to the captured images to communicate the process more effectively. Unfortunately, Mr. Bob wasnt familiar with how to format his comments to align to the proper terminology of VSM and has instead written a series of comments for you to distill the information from. (The information included has not been written in a cryptic way, the values may simply be presented in a less than desirable unit type for which you will need to translate or standardize them). On-site Analyst Observations: Unit: When processed, the coffee beans are referred to as a 'unit' of production. The exact measurement was 20Kg of coffee beans (post-processing) per unit. Therefore, each time a 'unit' is processed, exactly 20Kg of coffee beans were processed. Facility: Number of shifts per day: 2 Availability: 8 hours per shift (30-minute time loss to breaks per shift) Batch Size: 244 Average Demand: 400/day Weekly Demand: 2000 Raw materials supplier receives an automated electronic communication from our facility and takes 3 days to ship the order from the supplier to the manufacturing facility. Process Step 1: Hulling Two operators are required to run the coffee bean hulling machine. The machine can process exactly 20 units per hour. As the machine requires recalibration and a thorough cleaning between usage, the resultant setup time is 90 minutes between units. Due to the simplistic nature of this machine there is an observed 100% up time. Before passing to Process Step 2: cleaning approximately 800 units must be stored in inventory (WIP). *Hint: Normalize all time values to seconds and calculate the Per Unit Processing Time (Cycle Time + Setup Time). Pexels, C. (n.d.). [Hulling coffee beans]. Retrieved from https://www.pexels.com/photo/stainless-steel-roundcontainer-with-brown-powder-4820818/ Process Step 2: Cleaning A single operator runs the filtration basins. Each coffee bean unit is added to a large filtration device that uses long paddles to spin the hulled coffee beans, pushing debris and dust off. The unusable materials will filter through the large mesh sifter base leaving only cleaned beans that automatically exit the filtration basin into an attached storage container. For the purposes of this assessment we will assume that 20Kg of product is still the yield per unit. The filtration device is rated to process 800Kg of coffee beans per hour. *Hint, calculate UNITS (how many kg per unit) can be processed each hour. However, due to the machine becoming clogged with debris, resulting in the necessity of frequent cleaning, the rated Up-Time of this machine is only observed to be 80%. Additionally, loading a unit of beans (Setup Time) into the hopper took 12 seconds for each unit. Before passing to Process Step 3: Grading 12,000 Kg of product must be processed. *Hint, convert Kg to units for WIP Pexels, C. (n.d.). [Hulled coffee bean cleaning]. Retrieved from https://www.pexels.com/photo/stainless-steel-cup-on-whitemetal-table-4820730/ Process Step 3: Grading Each unit of coffee must next be placed through a grading device that will test for acidity, oil consistency and flavonoids. Each unit takes precisely 1 minute to process with a setup time of 8 seconds per unit. However, as this device works on compression and heat, the observed up-time is only 33% and is managed / tended by 1 operator. 8,000Kgs of coffee must be graded (WIP) before we can proceed to Process Step 4: Roasting. Pexels, C. (n.d.). [Gray and Blue Machine]. Retrieved from https://www.pexels.com/photo/engine-engineeringequipment-factory-633860/ Process Step 4: Roasting Mr. Bob requested support from the coffee roaster on how to fill out this section. These are the values as reported by the roaster (who just so happened to be a former VSM Expert). Cycle Time = 133 Seconds per unit Throughput = 60 seconds per min/133 seconds per unit = 0.45 units per minute Setup Time = 17 Seconds per unit Per unit processing time = 133 seconds + 17 seconds = 150 seconds Up-Time = 75% (22.5 hours @ 75% eff = 60,750 seconds) Operators = 2 WIP = 400 units Pexels, C. (n.d.). [Black and White Digital Device]. Retrieved from https://www.pexels.com/photo/black-and-white-digitaldevice-4820777/ Process Step 5: Packaging The final step in the process is heavily automated, requiring a single employee to align packaging, allowing the feeder machine to fill the package, and then heat seal the bag. Due to the simplicity of this device, a 100% up-time was reliably observed. To meet daily demand, we need to package and transfer the daily customer order of 400 units at the same time to Shipping. This stage had a longer than expected setup time as the company has opted to subdivide each unit in 20 separate 1Kg bags for resale to customer. Each of the 20, 1Kg bags, takes 4 seconds to fill and 2.3 seconds to setup. *Hint: Just because our co-worker (the observing Analyst) had decided to report the unit(s) as being repackaged into smaller bags does not mean that we will change our unit size. Our unit size stays the same and all calculations must be treated as such. If we have 20 * 1 Kg bags that take 2 seconds each to fill then we have 1 Unit (20 Kg) at 40 seconds (20 * 2 seconds). Apply this same concept to Setup Time. Pexels, C. (n.d.). [Man in Blue Dress Shirt Holding White Printer Paper]. Retrieved from https://www.pexels.com/photo/manin-blue-dress-shirt-holding-white-printer-paper-4820846/ Shipping No inventory is kept after processing. Goods are shipped directly to the customer facility from Packaging every day around 5pm. Pexels, C. (n.d.). [Man in Blue Denim Jacket and Blue Denim Jeans Holding Black and Yellow Hand Truck]. Retrieved from https://www.pexels.com/photo/man-in-blue-denim-jacketand-blue-denim-jeans-holding-black-and-yellow-hand-truck4820678/ Information Flow: All communications with customer/raw material supplier are electronic. Production Control submits a Weekly Order Form to the supplier. The Customer submits an Order Request. There is a daily order release to Step 1: Roasting All material is PUSHED.

Value Stream Map (VSM) Assignment (Individual) Description: This assessment has multiple objectives for student learning and skill(s) development: 1) This scenario will provide students with an academic-based case which is meant to; a. Afford a valuable hands-on experience in utilizing industry-standard tools b. Deepen student understanding of the interdependencies that exist between Business and Manufacturing 2) This deliverable will afford course faculty a chance to gauge student preparedness and ability to; a. Transcribe manufacturing scenarios to business-tool based solutions b. Properly employ best practices through the application of industry tools 3) This assessment is meant to assist in preparing students for more challenging evaluations, with heavier weights, that will be delivered throughout this course. Learning Outcomes: Through the completion of this deliverable students will achieve, in totality or in part, the following unit and/or course outcomes as itemized on the course outline. Unit and Course Outcomes: Course Outcome 3. Analyze process performance data using common industry tools to find opportunities to improve a business process. Unit Outcomes: 1.0 Lean Methods 1.2 Apply tools for eliminating waste from a business process. 1.8 Use various process analysis tools. Tasks: 1) Create a value stream map for the narrative found within the Assignment #1 folder a. On a separate tab you are to show all rough work for how the data box values were calculated 2) Answer the following group of questions (Include these questions on a second tab within VISIO file, during conversion to PDF they will appear as an additional page): 1. What is the TAKT time for this manufacturing cell? 2. What is the total production Lead Time? 3. What is the total throughput and cycle times for this manufacturing cell? 4. What is the maximum manufacturing capacity per week? Are we able to meet customer requirements? If we are unable to meet demand, which process failed to meet requirements? 5. What is the process cycle efficiency (PCE)? 6. In under 250 words, clearly describe the purpose of VSM mapping and provide a brief explanation as to how it would help an organization control processes and capacity manufacturing. Format Requirements: The following requirements are enforced for this assessment. Length1 of paper: N/A Number of files: 1 File Name: See O3 Student Submissions Naming Convention.pdf Audience and Tone: o Audience type; General o Tone; Professional Citation Style: o APA2 (required) Title Page: o Title, Course Code, Section, Student Name, Date, Version Font Style: o Body Size: 11pt o Font Style: Calibri Line Spacing: o 1.08pt (Microsoft Default) Margins: o Narrow setting (0.5) Document Format: o For each non-title page, a header (or footer) including; date, Course code, Student name o Dropbox submission through eConestoga o PDF The items included within the Format Requirements section will be included as a grading element for the associated rubric for Formatting evaluation even if not specifically listed on the rubric. Success Criteria: This assessment's overall weight can be found on the Instructional Plan (IP) and reflected within the eConestoga grade book. Any student that discovers a conflict existing between the IP and grade book shall notify their course faculty member. The entirety of your assessment must be recorded utilizing the Zoom Record functionality. For specifics on this process, please read the attached document Recording your Test with Zoom.PDF. Failure to record and upload said recording to the cloud may result in a grade of zero (0) being applied to this evaluation. The link for your cloud saved recording must be embedded as a hyperlink in the VISIO file, placed underneath of your VSM title. If your hyperlink to your cloud recording is not ready before submission deadline then you are to submit the hyperlink within a text file to the assignment dropbox once it is ready. You will not be deducted grades or penalized for late submission for the link being submitted after the deadline. The assessment grade will consist of the following criterion: Formatting Map Proper Shapes/Symbols used Map correct use of available data Map Total metrics; accurate, complete (5%) TAKT Time Total Lead Time Throughput/Cycle time Capacity Process Cycle efficiency (PCE) Short-Answer write-up 1 Page count does not include; cover page, table of content, large 2 For details on APA style referencing you are to visit format images, reference page(s) or bibliography https://apa.conestogac.on.ca/ For specific evaluation standards, students shall consult the associated rubric found in the Rubrics section of eConestoga. Resources: Microsoft VISIO (VSM Template) (1) narrative (PDF) file, this will be a unique file assigned to your cohort and will be available within the corresponding assignment sub-module, of your eConestoga course shell Grammarly premium is, at the time of writing this, free for use to all Conestoga students, you may login with your Conestoga credentials to receive automated writing and grammar assistance. The Writing Services center provides writing support through https://lib.conestogac.on.ca/writing-services o Downloadable PDF instructions on making an appointment with Conestoga Colleges Writing Services are located here: https://lib.conestogac.on.ca/ld.php?content_id=35144762