Acme Machining Co

Acme Machining Co.

Create a “Current Value Stream Map” recording the following: At each process  Cycle time  Set Up or changeover time  Observed inventory  Waiting time  Scrap 2. Create • Pie chart displaying value added & non-value added percentages

Acme Machining company produces several components for vehicle assembly plants. With operating costs of £50 – 00p per hour. This case concerns one product family, a vehicle disc brake in two types: one each for the off side (RH) and one for the near side (LH) for a custom built vehicle. These components are sent to the ChrisCar Custom Vehicle assembly plant (the customer). The ChrisCar company have suggested that due to market demand, they will be looking to increase the monthly order to 1,600 per month (double current output). Would the Acme Machining Company be in a position to respond.

Production Processes Acme’s processes for this product involve drilling, turning, grinding and painting forged brake disks. The components are then packed and shipped to the customer on a daily basis at a selling price of £100 – 00p each. Forgings are supplied by British Forgings Ltd. and deliveries to Acme arrive on Tuesdays and at a cost of £20 - 00p per forging.

Customer Requirements 800 pieces per month 400 per month of Type “LH” 400 per month of Type “RH” Customer plant operates on three shifts Palletized returnable tray packaging with 4 forgings in a tray and up to 5 trays on a pallet. The customer orders in multiples of trays. One daily shipment to the vehicle assembly plant by truck.

Work Time 20 days in a month three shift continuous operation in all production departments the working week is from 6am Monday to 10pm Friday Eight (8) hours every shift, with overtime if necessary Two 10-minute breaks during each shift as well as a 1 hour Lunch. Processes stop during breaks and lunch.

Production Control Department Receive ChrisCar’s 90/60/30-day forecasts and enters them on to MRP. Issues Acme’s 6-week forecasts to British Forgings Ltd. via MRP Secures forgings by weekly FAXed order release to ChrisCar Co. Receive daily firm order, WIP inventory levels, F/G inventory levels, and anticipated scrap and downtime. Issues weekly schedules to Drilling, Turning, Grinding, Painting and Inspection processes Issues daily shipping schedule to Shipping Department Process Information All processes occur in the following order and each piece goes through all processes.

Drill (Asquith – Radial Arm Drill) 3.2 feet arm length 12” column dia 5hp 40 – 2000 rpm Manual process with one operator Cycle Time: 8 minutes Set Time: 15 minutes Non-conformance: 8% Observed Inventory prior to drill 30 days of forgings, 1200 Prior to Drill: 1200 forgings After drill prior to turn: 40 pieces of Type “LH” finished stampings 24 pieces of Type “RH” finished stampings Distance to Turn 1 = 6m (part transition / waiting time 720hrs)

Turn 1 (Logan – Dial A Speed, Precision Lathe) 14” swing 30” centers 3hp 2500 max rpm with variable speed control. Manual process with one operator Cycle Time: 5 minutes Set Time: 7minutes Non-conformance: 10% Observed Inventory after turn 1 prior to turn 2: 46 pieces of Type “LH” finished stampings 24 pieces of Type “RH” finished stampings Distance to Turn 2 = 7m (part transition / waiting time 12.8 hrs)

Turn 2 (Weiler – Precision Lathe) 18” swing 31” centers 3.5 hp 2200 max rpm adjustable speed control Manual process with one operator Cycle Time: 5 minutes Set Time: 10 minutes Non-conformance: 4% Observed Inventory after turn 2 prior to grind 1: 110 pieces of Type “LH” 60 pieces of Type “RH” Distance to Grind 1 = 8m Non- conformance 4% (part transition / waiting time 17.5 hrs)

Grind 1 (Cincinnati Universal Grinder) 20” Swing 24” Centers Manual process with one operator Cycle Time: 10 minutes Set Time: 15 minutes Non-conformance: 6% Observed Inventory after grind 1 prior to grind 2: 140 pieces of Type “LH” 85 pieces of Type “RH” Distance to Grind 2 = 5m Non- conformance 6% (part transition / waiting time 70.8 hrs) Grind 2 (Landis Universal Grinder) 20” Swing 24” Centers Manual process with one operator Cycle Time: 15 minutes Set Time: 15 minutes Non-conformance: 3% Observed Inventory after grind 2 prior to turn 3: 12 pieces of Type “LH” 22 pieces of Type “RH” Distance to Turn 3 = 12m Non- conformance 3% (part transition /waiting time 112.5 hrs)

Turn 3 (Weiler – Precision Lathe) 18” swing 31” centers 3.5 hp 2200 max rpm adjustable speed control Manual process with one operator Cycle Time: 4minutes Set Time: 10minutes Non-conformance: 5% Observed Inventory After turn 3 prior to CMM : 17 pieces of Type “LH” 40 pieces of Type “RH” Distance to Inspect 1 = 8m Non- conformance 5% (part transition / waiting time 7.9 hrs) Inspect 1 (Brown & Sharp CMM) X axis 25.5” Y axis 39.3” Z axis 25.5” Manual process with one operator Cycle Time: 7 minutes Set Time: 12 minutes Non-conformance: 0% Observed Inventory After CMM prior to Mask: 17 pieces of Type “LH” 10 pieces of Type “RH” Distance to Mask = 18m Non- conformance 0% (part transition / waiting time 18 hrs)

Mask (Manual) Manual process with one operator Cycle Time: 15 minutes Set Time: 0 minutes Non-conformance: 3% Observed Inventory after mask prior to visual inspect: 30 pieces of Type “LH” 42 pieces of Type “RH” Distance to Inspect 2 = 4m Non- conformance 3% (part transition / waiting time 6.7 hrs)

Inspect 2 (Visual) Manual process with one operator Cycle Time: 3 minutes Set Time: 0 minutes Non-conformance: 0% Observed Inventory After visual inspect prior to paint : 18 pieces of Type “LH” 22 pieces of Type “RH” Distance to Paint = 6m Non- conformance 0% (part transition / waiting time 3.6 hrs) Paint (Gema – Fully automated Powder coating system) Capacity, 5 feet x 8 feet x 6feet Manual loading process with one operator Cycle Time: 120 minutes 10 parts per load Set Time: 8 minutes Non-conformance: 2% Observed Inventory After paint prior to final inspection: 25 pieces of Type “LH” 38 pieces of Type “RH” Distance to Final Inspection = 6m (part transition / waiting time 8 hrs)

Final Inspection (Visual) Manual process with one operator Cycle Time: 6 minutes Set Time: 0 Non-conformance: 5% Observed inventory waiting for shipment: 27 pieces of Type “LH” 28 pieces of Type “RH” Distance to Shipping = 6m (part transition / waiting time 6.3 hrs)

Shipping Department - Removes parts from finished goods warehouse and stages them on pallets for truck shipment to customer.

drill turn

le d in r p r le s a an i 4 ll ll g e ri i l o W d p il L dr

Cincinnti

Table B&S CMM grind

mask Landis

inspect receipt

Gemma paint system

despatch paint