styJuice Co$.$ Case

$1)$ Construct a current state VSM for the TastyJuice Co$.$ VSM data is given below. $($Draw by hand or MS$-$

word$/$ppt$/$excel$).$ Please see the symbols on page $3$ and $4.$

$2)$ Calculate the daily customer demand requirement per shift.

$3)$ Calculate available time per shift.

$4)$ Calculate the takt time $($in seconds$).$

$5)$ Calculate the production lead time for the process.

$6)$ Calculate the processing time for the process. $($Processing time is the sum of the cycle times for all given process

steps, ignore setup time in this case.$)$

$7)$ Calculate the processing time for each step. $($Processing time for each step $=$ cycle time plus setup time per unit.

Check the batch size before you calculate the setup time per unit$).$

$8)$ What is the capacity of each process step?

$9)$ Is there a process that is a bottleneck? If yes, which process is the bottleneck and why?

$10)$ What suggestions do you have to improve the process? Brainstorm within the team how you can use lean and

TOC to improve the process?

TASTYJUICE CO$.$ DATA SET

TastyJuice Co$.$ produces multiple types of juices for their customer DistribJuice, which is a juice distribution company.

This case concerns one type of juice: A mixed fruit juice called DeliciousDrink.

CUSTOMER REQUIREMENTS:

$-25,000$ bottles of juice per month

$-$ Customer plant operates on two shifts

$-$ Bottles are sent to DistribJuice in crates that hold $50$ bottles$/$crate$.$ Multiple cranes are sent to the customers.

$-$ Bi$-$weekly shipment to DistribJuice by truck $($once every two weeks$)$

WORK TIME:

$-24$ days in a month

$-$ Two shift operation in all production departments

$-$ Eight $(8)$ hours every shift.

$-$ Three $10-$minute breaks during each shift

$-$ Lunch time of $30$ min

$-$ Manual processes stop during breaks.

PRODUCTION PROCESSES:

$-$ TastyJuice's process for this product family involves $5$ steps: preparing ingredients for mixing, mixing, making

juice, bottling, and sealing. After sealing the bottles are shipped to DistribJuice on a bi$-$weekly basis.

$-$ The ingredients are supplied by JuiceSupply Co$.$

$-$ Deliveries from JuiceSupply are made to TastyJuice on Wednesdays.

TASTYJUICE PRODUCTION CONTROL DEPARTMENT:

$-$ TastyJuice receives DistribJuice$$s $180/90/30-$day forecasts and enters them to MRP

$-$ TastyJuice issues $4-$week forecasts to JuiceSupply Co$.$ via MRP

$-$ TastyJuice Secures ingredients by weekly order placed automatically through their ERP

$-$ TastyJuice receives daily firm order from DistribJuice

$-$ Tastyjuice issues weekly build schedules to Preparation, Mixing, Making Juice, Bottling and Sealing processes

$-$ TastyJuice issues bi$-$weekly shipping schedule to Shipping Department