Tasks: 1) START 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.

On-site Analyst Observations: Unit: When processed, the coffee beans are referred to as a 'unit' of production. The exact measurement was 25Kg of coffee beans (post-processing) per unit. Therefore, each time a 'unit' is processed, exactly 25Kg of coffee beans were processed. Facility: Number of shifts per day: 3 Availability: 8 hours per shift (30-minute time loss to breaks per shift) Batch Size: 250 Average Demand: 360/day Weekly Demand: 1800 Raw materials supplier receives an automated electronic communication from our facility, and takes 5 days to ship order to manufacturing facility. Process Step 1: Hulling A single operator runs the coffee bean hulling machine which can process exactly 22 units per hour. As the machine requires recalibration and a thorough cleaning between usage, the resultant setup time is 85 minutes. Due to the simplistic nature of this machine there is an observed 100% up time. Before passing to Process Step 2: cleaning approximately 750 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).

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 25Kg of product is still the yield per unit. The filtration device is rated to process 700 Kg of coffee beans per hour. *Hint, calculate UNITS (how many kg per unit) can be processedeach 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 75%. Additionally, loading a unit of beans (Setup Time) into the hopper took 17 seconds for each unit. Before passing to Process Step 3: Grading 10,000 Kg of product must be processed. *Hint, convert Kg to units for WIP

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 1.5 minutes to process with a setup time of 9 seconds per unit. However, as this device works on compression and heat, the observed up-time is only 35% and can only be tended to by 1 operator per shift. 7,500Kg's of coffee must be graded (WIP) before we can proceed to Process Step 4: Roasting.

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). C/T = 150 Seconds per unit Throughput = 60seconds per min/150 seconds per unit = 0.40 units per minute Setup Time = 19 Seconds per unit Per unit processing time = 150 seconds + 19 seconds = 169 seconds Up-Time = 80% (22.5 hours @ 80% eff = 64,800 seconds) Operators = 1 WIP = 500 units

Process Step 5: Packaging The final step in the process is heavily automated, requiring a single employee to simply 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 360 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 25 separate 1Kg bags for resale to customer. Each of the 25, 1Kg bags, takes 3 seconds to fill and 3.2 seconds to setup. *Hint: Just because our co-worker (the observing Analyst) haddecided to report the unit(s) as being repackaged into smaller bagsdoes not mean that we will change our unit size. Our unit size staysthe same and all calculations must be treated as such. If we have 25*1 Kg bags that take 3 seconds each to fill then we have 1 Unit (25Kg) at 60 seconds (25 * 3 seconds). Apply this same concept to Setup Time.

Shipping One shipment of 1,800 units per week.

Information Flow: All communications with customer/raw material producer are electronic. There is a daily order release to "Step 1: Hulling" and "Step 5: Packaging" All material is PUSHED.