Vernon Inc. has analyzed the setup time on its computer-controlled lathe. The setup requires changing the type of fixture that holds a part. The average setup time has been 140 minutes, consisting of the following steps:

Turn off machine and remove fixture from lathe	15	minutes
Go to tool room with fixture	15
Record replacement of fixture to tool room	18
Return to lathe	20
Clean lathe	20
Return to tool room	20
Record withdrawal of new fixture from tool room	12
Return to lathe	15
Install new fixture and turn on machine	5
Total setup time	140	minutes

a. A company plans to setup a machine to increase the productivity. The average setup time is 140 minutes. Do you think the management needs to minimize the setup time. Identify the reason that supports the answer.

1. Yes
2. No

a

Reason:

1. The setup time is not a concern of the company as it is not related to productivity of the company.
2. The setup time should be considered because long setup time leads to increased economic cost of the setup.
3. The cost incurred for setup can be ignored as it is related to machinery.
4. Long setup cost can be recovered as depreciation.

b.

A company plans to setup a machine to increase the productivity. The average setup time is 140 minutes. The company wishes to control the setup time. Identify the statement that suits the given situation.

1. Identify the wait time and non-value-added time and eliminate that with effective planning so that the setup time can be reduced.
2. Identify the machine that has less setup time.
3. Identify the laborers are contributing less to the setup process and eliminate them from the process.
4. None of the above.

c. How much time would be required for a setup, using your suggestion in (b)? ____--$ minutes

_________________________________________________________________________________________

Jackson Fabricators Inc. machines metal parts for the automotive industry. Under the traditional manufacturing approach, the parts are machined through two processes: milling and finishing. Parts are produced in batch sizes of 40 parts. A part requires 6 minutes in milling and 8 minutes in finishing. The move time between the two operations for a complete batch is 5 minutes.

Under the lean philosophy, the part is produced in a cell that includes both the milling and finishing operations. The operating time is unchanged; however, the batch size is reduced to 5 parts and the move time is eliminated.

Determine the value-added, non-value-added, and total lead times, and the value-added ratio under the traditional and lean manufacturing methods. If required, round percentages to one decimal place.

	Traditional Philosophy		Lean Manufacturing Philosophy
Value-added time		min		min
Non-value-added time		min		min
Total lead time		min		min
Value-added ratio (as a percent)		%		%