Calculate Lead Time Flint Fabricators Inc. machines metal parts for the automoti

Question

Calculate Lead Time

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 80 parts. A part requires 2 minutes in milling and 10 minutes in finishing. The move time between the two operations for a complete batch is 11 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) % %

Explanation / Answer

Traditional Philosophy Lean Manufacturing Philosophy Value-added time 2+10 =12 5+7 =12 Non-value-added time 12*(80-1)+11=959 12*(6-1) =60 Total lead time 959+12=971 12+60=72 Value-added ratio (as a percent) 12/971*100 = 1.24% 12/72*100=16.67%

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