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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 75 parts. A part requires 2 minutes in milling and 9 minutes in finishing. The move time between the two operations for a complete batch is 10 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 6 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

Solution:
Traditional Philosophy Lean Manufacturing Philosophy
Value-added time 11 Min 11 Min
Non-value-added time 824 Min 55 Min
Total lead time 835 Min 66 Min
Value-added ratio (as a percent) 1.3 % 16.7 %
Working Notes:
Traditional Philosophy
Value-added time = 2 min of Milling time + 9 min of finishing time
Value-added time = 11 min
Non-Value Added time = Value Added time X (Batch size - 1) + Move time
Non-Value Added time = 11 min X (75 - 1) + 10 min
Non-Value Added time = 814 min + 10 min
Non-Value Added time = 824 min
Lead time = Value Added time + Non-Value Added time
Lead time = 11 min + 824 min
Lead time = 835 min
Value-Added Ratio = Value Added time / Lead time
Value-Added Ratio = 11 min / 835 min
Value-Added Ratio = 0.0131736
Value-Added Ratio = 1.3 %
Lean Manufacturing Philosophy
Value-added time = 2 min of Milling time + 9 min of finishing time
Value-added time = 11 min
Non-Value Added time = Value Added time X (Batch size - 1) + Move time
Non-Value Added time = 11 min X (6 - 1) + 0 min
Non-Value Added time = 55 min + 0 min
Non-Value Added time = 55 min
Lead time = Value Added time + Non-Value Added time
Lead time = 11 min + 55 min
Lead time = 66 min
Value-Added Ratio = Value Added time / Lead time
Value-Added Ratio = 11 min / 66 min
Value-Added Ratio = 0.1666666
Value-Added Ratio = 16.7 %
Please feel free to ask if anything about above solution in comment section of the question.

ekkarill92 answered 1 year ago
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