TastyJuice Co$.$ Case

$1)$ Construct a current state VSM for the TastyJuice Co$.$ VSM data is given below.

$2)$ Please turn in a one$-$page memo to document your suggestions regarding the steps to take to improve the process.

$3)$ Upload both your VSM and the word document on Canvas.

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, with overtime if necessary

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

$-$ Manual processes stop during breaks

$-$ Unpaid lunch of $30$ min

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 b$-$weekly shipping schedule to Shipping Department

PROCESS INFORMATION:

All processes occur in the following order and each item goes through all processes.

$1)$ PREPARATION FOR MIXING

$-$ Manual process with one operator

$-$ Cycle Time: $40$ seconds

$-$ Changeover time: $1$ hour $($good piece to good piece$)$

$-$ Reliability: $85\%$

$-$ Observed Inventory: $7$ days of materials before preparation station

$-$ Observed inventory: $1000$ units $($Inventory after Prep for Mixing but before Mixing. Observed inventory is given for the inventory that immediate follows the workstation $($and before the next workstation$)$ unless otherwise noted

$2)$ MIXING

$-$ Automated process done with $1000$ ton mixer

$-$ Cycle lime: $10$ seconds

$-$ Changeover time: $30$ minutes

$-$ Reliability: $90\%$

$-$ Observed Inventory: $2000$ units

$3)$ JUICE MAKER

$-$ Automated process done with $1000$ ton juice maker

$-$ Cycle lime: $20$ seconds

$-$ Changeover time: $20$ minutes

$-$ Reliability: $95\%$

$-$ Observed Inventory: $3200$ units

$4)$ BOTTLING

$-$ Automated process done with bottling machine

$-$ Cycle lime: $60$ seconds

$-$ Changeover time: $60$ minutes

$-$ Reliability: $80\%$

$-$ Observed Inventory: $800$ units

$5)$ SEALING

$-$ Manual process with one operator

$-$ Cycle Time: $15$ seconds

$-$ Changeover time: $10$ minutes

$-$ Reliability: $100\%$

$-$ Observed Inventory: $2500$ units

$6)$ SHIPPING DEPARTMENT

Removes parts from finished goods warehouse and stages them for truck shipment to customer.