Acme stamping company produces several components for vehicle assembly plants. This case
concerns one product family: a steel instrument-panel bracket subassembly in two types: one each
for left hand and right hand drive versions of the same automobile model. These components are
sent to the State Street Vehicle Assembly Plant (the customer).
CUSTOMER
REQUIREMENTS:
• 18400 pieces per month
• 12000 per month of type “LH”
• 6400 per month of type “RH”
• Customer plant operates on two shifts
• Palletized returnable tray packing with 20 brackets in a tray
and up to 10 trays on a pallet
• The customer orders in multiples of trays
• One daily shipment to the assembly plant by truck
WORK TIME:
• 20 days in a month
• Two shift operation in all production departments
• Eight (8) hours every shift, with overtime if necessary
• Two 10 minute breaks during each shift
• Manual processes stop during breaks
• Unpaid lunch
PRODUCTION
PROCESS:
• Acme’s process for this product family involves stamping a
metal part followed by welding and subsequent assembly.
The components are then staged and shipped to the
vehicle assembly plant on a daily basis
• Switching between type “LH” (left hand drive) and type
“RH” (right hand drive) brackets requires 1 hour
changeover in stamping and 10-minute fixture change in
the welding processes.
• Steel coils are supplied by Michigan Steel Co.
• Deliveries are made to Acme on Tuesday and Thursday
•
ACME PRODUCTION
CONTROL
DEPARTMENT
• Receives state street’s 90/60/30 day forecast and enters them
to MRP
• Issues Acme 6 week forecast to Michigan Steel Co via MRP
• Secures coil steel by weekly Faxed order released to Michigan
Steel Co.
• Receives daily firm order from state street
• Generate MRP based weekly departmental requirements
based upon customer order, WIP inventory levels F/G
inventory level, and anticipated scrap and downtime
• Issues weekly build schedules to stamping, welding, and
assembly processes
• Issues daily shipping schedule to shipping department
PROCESS
INFORMATION
All processes occur in the following order and each piece goes
through all process. 1. STAMPING
(The press makes parts for many Acme products)
• Automated 200 ton press with coil (automatic material feed)
• Cycle time: 1 second (60 pieces per minute)
• Changeover time: 1 hour (good piece to good piece)
• Machine reliability: 85%
• Observed inventory:
▪ 5 days of coils before stamping
▪ 4600 pieces of type “LH” finished stampings
▪ 2400 pieces of type “RH” finished stampings

2. SPOT WELD WORKSTATION – I
   (dedicated to this product family)
   • Manual process with one operator
   • Cycle time: 39 second
   • Changeover time: 10 minutes (fixture change)
   • Machine reliability: 100%
   • Observed inventory:
   ▪ 1100 pieces of type “LH”
   ▪ 600 pieces of type “RH”
3. SPOT WELD WORKSTATION – II
   (dedicated to this product family)
   • Manual process with one operator
   • Cycle time: 46 second
   • Changeover time: 10 minutes (fixture change)
   • Machine reliability: 80%
   • Observed inventory:
   ▪ 1600 pieces of type “LH”
   ▪ 850 pieces of type “RH”
4. ASSEMBLY WORKSTATION – I
   (dedicated to this product family)
   • Manual process with one operator
   • Cycle time: 62 second
   • Changeover time: none
   • Machine reliability: 100%
   • Observed inventory:
   ▪ 1200 pieces of type “LH”
   ▪ 640 pieces of type “RH”
5. ASSEMBLY WORKSTATION – II
   (dedicated to this product family)
   • Manual process with one operator
   • Cycle time: 40 second
   • Changeover time: none
   • Machine reliability: 100%
   • Observed finished goods inventory in warehouse:
   ▪ 2700 pieces of type “LH”
   ▪ 1440 pieces of type “RH”
6. SHIPPING DEPARTMENT
   Removes parts from finished goods warehouse and stages them for
   truck shipment to customer.
   Information flow diagram is provided below.
   Production Control Start
   Satmping
   Welding#1
   Welding#2
   Assembly#1
   Assembly#2
   Inventory
   Coil
   Loaded
   Inventor
   y (L,R)
   Inventory
   (L,R)
   Inventory
   (L,R)
   End
   Inventory
   (L,R)
   Assembly#2
   Shipping
   Questions:
7. Draw Current State and Future State Map by using Companion Software. (Take Screen Shots
   and paste in word file)
8. Calculate the time in seconds for all processes and the total cycle time.
9. Identify the Value Added, Non – Value Added activities times and Waiting time Value stream
   activities. Show detail calculations for Material and Information flow in Current and Future
   State Map. (Upload Pdf File)