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 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.

Determine the value-added, non-value-added, and total lead times, and the value-added ratiounder 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)		%		%

Answer 1

Answer:

We have to Determine the value-added, non-value-added, and total lead times, and the value-added ratio under the traditional and lean manufacturing methods.

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 :

traditional:

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

Lean:

10(4-1) = 30 min

3) Total lead time :

Traditional :

Value added + Non value added = 10+849 = 859 min

Lean:

10+30 = 40 min.

4) Value added ratio:

Traditional:

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

Lean = 10 / 40 = 25%.