Calculate Lead Time Flint Fabricators Inc. machines metal parts for the automotive industry. Under the traditional...

Calculate Lead Time

Flint 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 80 parts. A part requires 4 minutes in milling and 8 minutes in finishing. The move time between the two operations for a complete batch is 9 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 4 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)		%		%

Solutions

Expert Solution

Traditional Philosophy:

1. Value Added Time: Milling Time + Finishing Time

Value Added Time: 4 Min + 8 Min

Value Added Time: 12 Minutes

2. Non Value Added Time: Move Time + Value Added Time * (Batch Size - 1)

Non Value Added Time: 9 + 12 * (80 - 1)

Non Value Added Time: 957 Minutes

3. Total Lead Time = Non Value Added + Valued Added time = 957 + 12 = 969 Minutes

4. Value added ratio = Value Added / Total Lead time = 12 / 969

Value added ratio = 1.3%

Lean Manufacturing Philosophy:

1. Value Added Time: Milling Time + Finishing Time

Value Added Time: 4 Min + 8 Min

Value Added Time: 12 Minutes

2. Non Value Added Time: Move Time + Value Added Time * (Batch Size - 1)

Non Value Added Time: 0 + 12 * (4 - 1)

Non Value Added Time: 36 Minutes

3. Total Lead Time = Non Value Added + Valued Added time = 36 + 12 = 48 Minutes

4. Value added ratio = Value Added / Total Lead time = 12 / 48

Value added ratio = 25.0%

ekkarill92 answered 1 year ago

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