Question

# Calculate Lead Time Flint Fabricators Inc. machines metal parts for the automotive industry. Under the traditional...

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 85 parts. A part requires 2 minutes in milling and 8 minutes in finishing. The move time between the two operations for a complete batch is 9 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 4 parts and the move time is eliminated.

 Particulars Traditional philosophy Lean manufacturing philosophy Value added time 10 min 10 min Non value added time 849 min 30 min Total lead time 859 min 40 min Value added ratio 1.16% 25%

Working notes:

1) Value added time = 2 min in milling + 8 min In finishing = 10 min.

2) Non value added time :

9 min+10 min(85-1) = 849 min

Lean:

10(4-1) = 30 min

Lean:

10+30 = 40 min.

Value added / Total lead time = 10 / 859 = 1.16%

Lean = 10 / 40 = 25%.