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 60 parts. A part requires 3 minutes in milling and 6 minutes in finishing. The move time between the two operations for a complete batch is 7 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) | % | % |
ANSWER:
Traditional Philosophy |
Lean Manufacturing Philosophy |
|
Value-added time |
3+6 =9 |
3+6=9 |
Non-value-added time |
9*(60-1)+7=538 |
9*(6-1) =45 |
Total lead time |
538+9=547 |
9+45=54 |
Value-added ratio (as a percent) |
9/547*100 = 1.64% |
9/54*100=16.67% |
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