Answer Happy

Two 15-min break periods, All the processes stop during these break periods. Production control department The department is required to perform the following actions(by fax or printed form): Receives a monthly forecast from the buyer and enters it into the SAP system. Receives weekly order from the buyer, Sends the 8-week forecast to the raw material supplier, Replenishes the raw sheets by a monthly order, Generates the MRP-based weekly requirements, Sends weekly operations schedules to all the departments. Production processes: The production line consists of the following processes. All the processes occur in the following order and each part should visit all of the stations Question 1): Study the problem carefully and then you need to draw the future state map based on the current situation. Show all your work. Case description: AB Company for producing refrigerators is in the process of implementing the lean concepts. As a major step to convert its traditional production system to a lean one is to develop the current state map. The company produces different models of refrigerators but they decided to start with only one product family that contains two models: model 1501 and model 3001. The final products are sent directly to the buyer XY once a week while the sheets, raw materials, are received from the vendor MN one time every two weeks. Buyer's demand 7200 units per month (4000 units of type 1 501 and 3200 units of type 3001) The pallet can hold up to 4 refrigerators. The buyer receives one weekly shipment from the company, Work time 20 day per month One 8-hr shift per day Overtime is allowed Process Name Sheets bending and cutting Required labor 3 Cycle time (sec.) 25 Changeover time (min.) 30 Up-time 60% Observed inventory 8 days of raw sheets 2 days of cut sheets Process Name Base assembly Required labor 1 Cycle time (sec.) 30 Changeover time (min.) 0 Up-time 95% Observed inventory 4 days Process Name Insulation foaming Required labor 1 Cycle time (sec.) 60 Changeover time (min.) 25 Up-time 85% Observed inventory 2 days
Process Name Required labor Cycle time (sec.) Changeover time (min.) Up-time Observed inventory Cell + door assembly 1 95 0 100% 3 days Process Name Required labor Cycle time (sec.) Changeover time (min.) Up-time Observed inventory Accessory insertion 1 32 0 95% 2 days Process Name Required labor Cycle time (sec.) Changeover time (min.) Up-time Observed inventory Packing 1 65 0 100% 4 Process Name Engine + condenser insertion Required labor 2 Cycle time (sec.) 85 Changeover time (min.) 0 Up-time 100% Observed inventory 3 days For security reasons, gas insertion is done at a separate station which operates in 3 shifts. Parts are shipped and received daily to/from this station Process Name Gas insertion (Has to go to a special station) Required labor 1 Cycle time (sec.) 265 Changeover time (min.) 5 Up-time 90% Working time 3 shifts Observed inventory Process Name Firal assembly Required labor 2 Cycle time (sec.) 96 Changeover time (min.) 0 Up-time 100% Observed inventory 2 days Process Name Testing Required labor 1 Cycle time (sec.) 40 Changeover time (min) 5 Up-time 90% Observed inventory 2 days 5 days