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Instructions and data for creating a value stream map for the lean systems module (ie450) of a 4th year industrial engineering b.e program. The case study focuses on abc engineering limited, which produces fabricated parts for apex motor manufacturers. Students are required to analyze the current state of the production process, identify improvement opportunities, and calculate the value-add ratio. The document also includes instructions for exam questions related to lean thinking, 5-s process, and various lean manufacturing concepts.
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Exam Code(s) 4BI Exam(s) 4 th^ Year B.E Industrial Engineering
Module Code(s) IE Module(s) Lean Systems
Paper No. I
External Examiner(s) Professor Antony Internal Examiner(s) Dr D O’Sullivan Prof J Sheil Mr C O’Reilly
No. of Pages 4 + cover Course Coordinator Department
Prof J Sheil Industrial Engineering
Requirements None
Carefully examine ABC Engineering Limited scenario, which is documented on page 4 of this paper.
(i) Produce a current state Value Stream map from this data, depicting both the material and information flows. Include a timeline at the bottom of your map, showing the total lead-time from material receipt to delivery of finished goods to the distribution centre. Calculate, and present, the Value-Add ratio as a percentage of total processing time against total lead-time.
(ii) Identify and describe some of the improvement opportunities that can be applied to the current state processes.
[Note: A list of all icons required to produce the current state map is provided on page 5 of this paper]
(i) The elimination of waste is one of the fundamental objectives in creating flow and building a Lean System. List and describe the 8 types of waste associated with Lean Thinking and explain, using examples where possible, the primary causes for these wastes.
(ii) List and describe each of the elements of the ‘5-S process’ and explain why 5-S is useful as a starting point for a Lean implementation.
The owners of the Great Bread Company are experiencing issues with meeting customer demand and need you to assess their processes given the following information and answer the relevant questions as outlined below.
MixinMixingg Proofing Proofing BakinBakingg PackaPackaginge &g Ship
In the mixing stage, all of the ingredients are combined to form the dough. The dough must then rise in a controlled environment called a proofing oven. The bread is then formed into loaves and baked. In the final stage, the bread is packaged prior to distribution.
–5 days per week, 3 x 8hr shifts per day –Each shift receives a 30-minute paid lunch –Each shift receives two 15-minute paid breaks
Question 1 - Value Stream Mapping Case Study:
ABC Engineering Limited produces fabricated parts that are supplied to Apex Motor Manufacturers. The production process consists of four primary operations: (1) Machining, (2) Forming, (3) Polishing and (4) Finishing. Secondary operations consisting of Batch Record Reviews are also performed.
Raw material (sheet metal) is received from the supplier once every week, and it is stored in a warehouse for 3 days before being used in production.
The production process starts with machining the sheet metal parts; these are then bended/formed into their necessary configurations. The inventory queue between Machining and Bending is approximately 10 days. After Bending, the products sit in an inventory queue, for approximately 7 days. The product is pushed to the next operation, which is Polishing. After Polishing, the product awaits Batch Record Review. This operation takes approximately 2 days. Once reviewed, the product sits in inventory for 12 days prior to being staged for Finishing. After Finishing, there is another Batch Record Review process. This operation takes approximately 5 days. Once Batch Record Review is completed the product is shipped, on a weekly basis, to Apex Motor Manufacturers. The average transit time is 2 days.
Current State Data:
Run Time:
Performance Rates:
Scheduling Production control schedules a firm based on a two month rolling forecast and weekly updates sent electronically by e-mail
Customer Demand: Total annual demand is 80,000 parts/year
Work Time:
Staffing Levels:
Polishing = 5 Finishing = 10
Scrap Uptime Change-over Time Machining 2% 65% 3 Hrs Bending 8% 90% 30 mins Polishing 3% 70% N/A Finishing 5% 70% 10 mins
Current state Value Stream mapping icons:
