Answer Happy

Question: Draw value stream map. A geographically remote gourmetcoffee bean manufacturer has contacted you, a ProductionSpecialist, requesting that you draft a VSM for their facility sothat they can better understand their current throughput andoperational performance. This is a brand-new production facilitythat this organization has custom built to meet the demand of a newhigh-volume customer, before the facility was developed, aninternal Analyst team sat down and calculated the exact yield andmachinery needed to meet the customer’s needs. However, after amonth of operation there appears to be a discrepancy in therequired production quantity and the projected production levels.You have been called in to verify the work of the Analyst team anddetermine if they made an error in their calculations. Unable tophysically access the facility, you opted to send your trustedco-worker, Billy Bob, to observe and document the process as it iscompleted. During Mr. Bob’s time in the facility, he decided totake a series of photos and fill-out his comments directly next tothe captured images to communicate the process more effectively.Unfortunately, Mr. Bob wasn’t familiar with how to format hiscomments to align to the proper terminology of VSM and has insteadwritten a series of comments for you to distill the informationfrom. (The information included has not been written in a crypticway, the values may simply be presented in a less than desirableunit type for which you will need to translate or standardizethem). Unit: When processed, the coffee beans are referred to as a'unit' of production. The exact measurement was 20Kg of coffeebeans (post-processing) per unit. Therefore, each time a 'unit' isprocessed, exactly 20Kg 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: 244 •Average Demand: 400/day • Weekly Demand: 2000/day Raw materialssupplier receives an automated electronic communication from ourfacility, and takes 5 days to ship order to manufacturing facility.Process Step 1: Hulling A single operator runs the coffee beanhulling machine which can process exactly 20 units per hour. As themachine requires recalibration and a thorough cleaning betweenusage, the resultant setup time is 90 minutes. Due to thesimplistic nature of this machine there is an observed 100% uptime. Before passing to Process Step 2: cleaning approximately 800units must be stored in inventory (WIP). *Hint: Normalize all timevalues to seconds and calculate the Per Unit Processing Time (CycleTime + Setup Time). Process Step 2: Cleaning A single operator runsthe filtration basins. Each coffee bean unit is added to a largefiltration device that uses long paddles to spin the hulled coffeebeans, pushing debris and dust off. The unusable materials willfilter through the large mesh sifter base leaving only cleanedbeans that automatically exit the filtration basin into an attachedstorage container. For the purposes of this assessment we willassume that 20Kg of product is still the yield per unit. Thefiltration device is rated to process 800Kg of coffee beans perhour. *Hint, calculate UNITS (how many kg per unit) can beprocessed each hour. However, due to the machine becoming cloggedwith debris, resulting in the necessity of frequent cleaning, therated Up-Time of this machine is only observed to be 80%.Additionally, loading a unit of beans (Setup Time) into the hoppertook 12 seconds for each unit. Before passing to Process Step 3:Grading 12,000 Kg of product must be processed. *Hint, convert Kgto units for WIP Process Step 3: Grading Each unit of coffee mustnext be placed through a grading device that will test for acidity,oil consistency and flavonoids. Each unit takes precisely 1 minuteto process with a setup time of 8 seconds per unit. However, asthis device works on compression and heat, the observed up-time isonly 33% and can only be tended to by 1 operator per shift.8,000Kg’s of coffee must be graded (WIP) before we can proceed toProcess Step 4: Roasting. Process Step 4: Roasting Mr. Bobrequested support from the coffee roaster on how to fill out thissection. These are the values as reported by the roaster (who justso happened to be a former VSM Expert). C/T = 133 Seconds per unitThroughput = 60seconds per min/133 seconds per unit = 0.45 unitsper minute Setup Time = 17 Seconds per unit Per unit processingtime = 133 seconds + 17 seconds = 150 seconds Up-Time = 75% (22.5hours @ 75% eff = 60,750 seconds) Operators = 1 WIP = 400 unitsProcess Step 5: Packaging The final step in the process is heavilyautomated, requiring a single employee to simply align packaging,allowing the ‘feeder machine’ to fill the package, and then heatseal the bag. Due to the simplicity of this device, a 100% up-timewas reliably observed. To meet daily demand, we need to package andtransfer the daily customer order of 400 units at the same time toShipping. This stage had a longer than expected setup time as thecompany has opted to subdivide each unit in 20 separate 1Kg bagsfor resale to customer. Each of the 20, 1Kg bags, takes 2 secondsto fill and 2.3 seconds to setup. *Hint: Just because our co-worker(the observing Analyst) had decided to report the unit(s) as beingrepackaged into smaller bags does not mean that we will change ourunit size. Our unit size stays the same and all calculations mustbe treated as such. If we have 20 * 1 Kg bags that take 2 secondseach to fill then we have 1 Unit (20 Kg) at 40 seconds (20 * 2seconds). Apply this same concept to Setup Time. One shipment of2,000 units per week. Information Flow: • All communications withcustomer/raw material producer are electronic. • There is a dailyorder release to “Step 1: Hulling” and “Step 5: Packaging” • Allmaterial is PUSHED. Question: Draw value stream map and can someonehelp me to calculate this 1.) What is the TAKT time for thismanufacturing cell? 2.) What is the total production Lead Time? 3.)What is the total throughput and cycle times for this manufacturingcell ? 4.) What is the maximum manufacturing capacity per week? Arewe able to meet customer requirements? If we are unable to meetdemand, which process failed to meet requirements? 5.) What is theprocess cycle efficiency (PCE)? 6.) In under 250 words, clearlydescribe the purpose of VSM mapping and provide a brief explanationas to how it would help an organization control processes andcapacity manufacturing.