Question

DataSpan, Inc., automated its plant at the start of the current year and installed a flexible manufacturing system. The company is also evaluating its suppliers and moving toward Lean Production. Many adjustment problems have been encountered, including problems relating to performance measurement. After much study, the company has decided to use the performance measures below, and it has gathered data relating to these measures for the first four months of operations.

	Month
	1		2		3		4
Throughput time (days)	?		?		?		?
Delivery cycle time (days)	?		?		?		?
Manufacturing cycle efficiency (MCE)	?		?		?		?
Percentage of on-time deliveries	84	%	79	%	76	%	73	%
Total sales (units)	2530		2421		2297		2210

Management has asked for your help in computing throughput time, delivery cycle time, and MCE. The following average times have been logged over the last four months:

	Average per Month (in days)
	1		2		3		4
Move time per unit	0.7		0.4		0.5		0.5
Process time per unit	3.3		3.1		2.9		2.7
Wait time per order before start of production	24.0		26.3		31.0		33.4
Queue time per unit	5.0		5.9		6.9		8.1
Inspection time per unit	0.4		0.6		0.6		0.4

1. Evaluate the company’s performance over the last four months. (Indicate the effect of each trend by selecting "Favorable" or  "Unfavorable" or "None" for no effect (i.e., zero variance).

	The Throughput Time measure displays trends The Delivery cycle time—days measure displays trends Manufacturing cycle efficiency—days measure displays trends

2-a. (Month 5) Refer to the move time, process time, and so forth, given for month 4. Assume that in month 5 the move time, process time, and so forth, are the same as in month 4, except that through the use of Lean Production the company is able to completely eliminate the queue time during production. Compute the new throughput time and MCE.

2-b. (Month 6) Refer to the move time, process time, and so forth, given for month 4. Assume in month 6 that the move time, process time, and so forth, are again the same as in month 4, except that the company is able to completely eliminate both the queue time during production and the inspection time. Compute the new throughput time and MCE.

(Round your answers to 1 decimal place.)

	Month 5 Month 6 Throughput time days days Manufacturing cycle efficiency (MCE) % %

3-a. Compute the throughput time for each month.
3-b. Compute the delivery cycle time for each month.
3-c. Compute the manufacturing cycle efficiency (MCE) for each month.

(Round your answers to 1 decimal place.)

	Throughput Time Delivery Cycle Time Manufacturing Cycle Efficiency (MCE) Month 1 days days % Month 2 days days % Month 3 days days % Month 4 days days %

Answer 1

1	Unfavorable trends
	Unfavorable trends
	Unfavorable trends
2 (a)		5 Month
	Throughput time- days :
	Process time	2.7
	Inspection time	0.4
	Move time	0.5
	Queue time	0
	Total throughput time	3.6
	MCE:
	Process time / Throughput time (2.7/3.6*100)	75
b		6 Month
	Throughput time- days :
	Process time	2.7
	Inspection time	0
	Move time	0.5
	Queue time	0
	Total throughput time	3.2
	MCE:
	Process time / Throughput time (2.7/3.2*100)	84.4
3 (a)	Throughput time for each month
		Month
		1	2	3	4
	Throughput time- days :
	Process time	3.3	3.1	2.9	2.7
	Inspection time	0.4	0.6	0.6	0.4
	Move time	0.7	0.4	0.5	0.5
	Queue time	5	5.9	6.9	8.1
	Total throughput time	9.4	10	10.9	11.7
(b)	Delivery cycle item for each month
		Month
		1	2	3	4
	Delivery cycle time-days:
	Wait time from order to start of production	24	26.3	31	33.4
	Throughput time	9.4	10	10.9	11.7
	Total delivery cycle time	33.4	36.3	41.9	45.1
c	manufacturing cycle efficiency for each month
		Month
		1	2	3	4
	MCE:
	Process time / Throughput time	35.1	31	26.6	23.1
		(3.3/9.4*100)	(3.1/10*100)	(2.9/10.9*100)	(2.7/11.7*100)