Variables and Formulas

Lean Manufacturing: A systematic method for waste minimization within a manufacturing system without sacrificing productivity.

Value$-$Added Steps: Steps in a process that directly contribute to the product's functionality or quality.

Non$-$Value$-$Added Steps: Steps in a process that do not directly contribute to the product's functionality or quality.

Concepts

Lean Manufacturing Principles:

Identify value from the customer's perspective.

Map the value stream.

Create flow by eliminating waste.

Pull production from the customer.

Pursue perfection.

Main Response

Let's evaluate the tea process workflow and identify non$-$value$-$added steps based on lean manufacturing principles:

Step $1$: Workers pick tea leaves

Value$-$Added: Yes, this step directly contributes to the product's quality and functionality.

Step $2$: Leaves are put into $50$ kg bags

Value$-$Added: Yes, this step is necessary for handling and transporting the tea leaves.

Step $3$: Bags are moved to a processing area

Value$-$Added: Yes, this step is necessary for the tea leaves to undergo further processing.

Step $4$: Bags of tea are reweighed

Value$-$Added: No$,$ this step does not directly contribute to the product's functionality or quality. It can be considered a non$-$value$-$added step, as it only adds time and effort to the process.

Step $5$: Leaves are spread across pans and troughs

Value$-$Added: Yes, this step is necessary for the withering process.

Step $6$: Leaves are withered on pans

Value$-$Added: Yes, this step is necessary for the tea leaves to lose moisture and develop flavor.

Step $7$: Leaves are cooled

Value$-$Added: Yes, this step is necessary to prevent further moisture loss and damage to the tea leaves.

Step $8$: Leaves are removed from pans and reweighed

Value$-$Added: No$,$ this step does not directly contribute to the product's functionality or quality. It can be considered a non$-$value$-$added step, as it only adds time and effort to the process.

Step $9$: Leaves are moved onto special trays and rolled

Value$-$Added: Yes, this step is necessary for the tea leaves to undergo rolling and breaking cell walls, which releases enzymes and initiates oxidation.

Step $10$: Leaves go through a first drying

Value$-$Added: Yes, this step is necessary to stop the oxidation process and preserve the tea's color and flavor.

Step $11$: Leaves are cooled

Value$-$Added: Yes, this step is necessary to prevent further moisture loss and damage to the tea leaves.

Step $12$: Leaves are put into trays for a second drying

Value$-$Added: Yes, this step is necessary to complete the drying process and ensure the tea leaves are stable for storage.

Step $13$: Leaves are removed from trays and reweighed

Value$-$Added: No$,$ this step does not directly contribute to the product's functionality or quality. It can be considered a non$-$value$-$added step, as it only adds time and effort to the process.

Step $14$: Poor quality leaves are thrown away

Value$-$Added: Yes, this step is necessary to ensure only high$-$quality tea leaves are packaged and shipped.

Step $15$: Leaves are visually inspected

Value$-$Added: Yes, this step is necessary to ensure only high$-$quality tea leaves are packaged and shipped.

Step $16$: Leaves are moved to an oxidizing area

Value$-$Added: Yes, this step is necessary for the tea leaves to undergo oxidation, which contributes to the tea's flavor and color.

Step $17$: Leaves are oxidized

Value$-$Added: Yes, this step is necessary for the tea leaves to develop their unique flavor and color profiles.

Step $18$: Leaves get a final drying to complete the oxidizing process

Value$-$Added: Yes, this step is necessary to stop the oxidation process and preserve the tea's color and flavor.

Step $19$: Leaves are cooled

Value$-$Added: Yes, this step is necessary to prevent further moisture loss and damage to the tea leaves.

Step $20$: Leaves are sent to packaging and shipping

Value$-$Added: Yes, this step is necessary to prepare the tea leaves for distribution and sale.

Step $21$: Leaves are weighed

Value$-$Added: Yes, this step is necessary to ensure accurate packaging and pricing.

Step $22$: Leaves are sorted: small, misshaped, or discolored tea leaves are discarded

Value$-$Added: Yes, this step is necessary to ensure only high$-$quality tea leaves are packaged and shipped.

Step $23$: Leaves are weighed

Value$-$Added: Yes, this step is necessary to ensure accurate packaging and pricing.

Step $24$: Leaves get a second sorting

Value$-$Added: Yes, this step is necessary to ensure only high$-$quality tea leaves are packaged and shipped.

Step $25$: Leaves are put into paper tea bags and sealed

Value$-$Added: Yes, this step is necessary for packaging and preparing the tea leaves for sale.

Step $26$: Tea bags are wrapped in paper packets

Value$-$Added: Yes, this step is necessary for protecting the tea bags and providing a convenient packaging format.

Step $27$: Tea bags are sealed

Value$-$Added: Yes, this step is necessary for ensuring the tea bags are securely closed and ready for distribution.

Step $28$: Wrapped tea bags are sorted into cardboard packs of $20$

Value$-$Added: Yes, this step is necessary for organizing and packaging the tea bags for sale.

Step $29$: Cardboard packs are sealed and wrapped in plastic

Value$-$Added: Yes, this step is necessary for protecting the tea bags during transportation and storage.

Step $30$: Boxes are sorted into shipping boxes

Value$-$Added: Yes, this step is necessary for organizing and preparing the tea bags for distribution.

Step $31$: Shipping boxes are wrapped and sealed ready to be shipped

Value$-$Added: Yes, this step is necessary for ensuring the tea bags are securely packaged and ready for transportation.

Conclusion

Based on the lean manufacturing principles, the following steps can be considered non$-$value$-$added:

Reweighing the tea leaves $($Steps $4,8,13)$

These steps do not directly contribute to the product's functionality or quality. They only add time and effort to the process. To improve the tea process workflow, these non$-$value$-$added steps should be minimized or eliminated. This can be achieved by implementing more efficient weighing methods or integrating the weighing process into other steps in the workflow.

based on these changes explain the implications both positive and negative of removing or changing these steps from the process flowchart and explain how these changes would help alignment to the TBL