reduction annually over the next $2$ years for panels A and $B.$ At present, they are running a batch$-$

type production with a push system. They believe they can achieve the targets through $5S,$

autonomous maintenance, quick change$-$over, and continuous production. They are running a day

shift with a net available production time of $420$ minutes. The team gathers appropriate data, which

is shown in the below tables. There are two value streams $-$ one for $A$&$B$ and the other for $C.$ Your

focus will be on $A$&$B.$

The smallest panel does not cure in the oven. It is cured at room temperature for $24hrs.$

a$.$ Based on the above Routing table, how many value streams do you need? Explain.

b$.$ Calculate the total daily requirement $($based on $20$ days$/$month$)$ for A&B$.$ Also, calculate

the individual daily requirements for A and $B.$

Considering only value stream $A$&$B$ from here on:

c$.$ What is the flow time in minutes?

d$.$ Calculate the value stream takt time $(min)$ and the pitch based on the $2$ pack$-$out quantity.

e$.$ Is the takt time achievable based on the capacity for heat treating? Explain$/$Quantify$.$

f$.$ The present state shows an imbalance in the production line. Since the company is trying

to move towards a continuous flow, propose a new solution without overproduction. The

processing time for heat treatment is predominantly due to processing itself $-$ curing. This

means that even if you could change the number of operators at Heat Treatment, the

cycle time would remain approximately the same. As a new Company initiative, consider

that every station will require $15$ min of inspection time. Sketch the final assembly line

and the new cycle $/$takt time chart. Versatile Composites wants $100\%-$line efficiency.

g$.$ Sketch your layout showing operator$/$material flow inside the workstations.

h$.$ Calculate the production ratio based on the Heijunka system for leveling production.

i$.$ How will you sequence production over the $1$ shift period? Demonstrate using a Heijunka

box for $1$ cycle.