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    Acme Stamping Data Set

    Uploaded by

    Mazhar Farid
    The document describes Acme Stamping Company's production process for left and right-hand instrument panel brackets. It details the customer requirements of 18,400 pieces per month (12,000 LH, 6,400 RH), production time of 20 days per month worked over two shifts, and the multi-step production process involving stamping, welding, assembly, and shipping. Inventory levels are provided for each step in the production process.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd

    Acme Stamping Data Set

    Uploaded by

    Mazhar Farid
    42 views5 pages
    The document describes Acme Stamping Company's production process for left and right-hand instrument panel brackets. It details the customer requirements of 18,400 pieces per month (12,000 LH, 6,400 RH), production time of 20 days per month worked over two shifts, and the multi-step production process involving stamping, welding, assembly, and shipping. Inventory levels are provided for each step in the production process.

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    The document describes Acme Stamping Company's production process for left and right-hand instrument panel brackets. It details the customer requirements of 18,400 pieces per month (12,000 LH, 6,400 RH), production time of 20 days per month worked over two shifts, and the multi-step production process involving stamping, welding, assembly, and shipping. Inventory levels are provided for each step in the production process.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    42 views5 pages

    Acme Stamping Data Set

    Uploaded by

    Mazhar Farid
    The document describes Acme Stamping Company's production process for left and right-hand instrument panel brackets. It details the customer requirements of 18,400 pieces per month (12,000 LH, 6,400 RH), production time of 20 days per month worked over two shifts, and the multi-step production process involving stamping, welding, assembly, and shipping. Inventory levels are provided for each step in the production process.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
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    ACME STAMPING DATA SET

    Acme stamping company produces several components for vehicle assembly plants. This case
    concerns one product family: a steel instrument-panel bracket subassembly in two types: one
    each for left hand and right hand drive versions of the same automobile model. These
    components are sent to the State Street Vehicle Assembly Plant (the customer).

    CUSTOMER  18400 pieces per month


    REQUIREMENTS:  12000 per month of type “LH”
     6400 per month of type “RH”
     Customer plant operates on two shifts
     Palletized returnable tray packing with 20 brackets in a tray
    and up to 10 trays on a pallet
     The customer orders in multiples of trays
     One daily shipment to the assembly plant by truck

    WORK TIME:
     20 days in a month
     Two shift operation in all production departments
     Eight (8) hours every shift, with overtime if necessary
     Two 10 minute breaks during each shift
     Manual processes stop during breaks
     Unpaid lunch

    PRODUCTION  Acme’s process for this product family involves stamping a


    PROCESS:
    metal part followed by welding and subsequent assembly.
    The components are then staged and shipped to the
    vehicle assembly plant on a daily basis
     Switching between type “LH” (left hand drive) and type
    “RH” (right hand drive) brackets requires 1 hour
    changeover in stamping and 10-minute fixture change
    in the welding processes.
     Steel coils are supplied by Michigan Steel Co.
     Deliveries are made to Acme on Tuesday and Thursday

    ACME PRODUCTION  Receives state street’s 90/60/30 day forecast and enters them
    CONTROL to MRP
    DEPARTMENT
     Issues Acme 6 week forecast to Michigan Steel Co via MRP
     Secures coil steel by weekly Faxed order released to Michigan
    Steel Co.
     Receives daily firm order from state street
     Generate MRP based weekly departmental requirements
    based upon customer order, WIP inventory levels F/G
    inventory level, and anticipated scrap and downtime
     Issues weekly build schedules to stamping, welding, and
    assembly processes
     Issues daily shipping schedule to shipping department

    PROCESS All processes occur in the following order and each piece goes
    INFORMATION through all process. 1. STAMPING

    (The press makes parts for many Acme products)

    • Automated 200 ton press with coil (automatic material feed)


    • Cycle time: 1 second (60 pieces per minute)
    • Changeover time: 1 hour (good piece to good piece)
    • Machine reliability: 85%
    • Observed inventory:
    ▪ 5 days of coils before stamping
    ▪ 4600 pieces of type “LH” finished stampings
    ▪ 2400 pieces of type “RH” finished stampings

    2. SPOT WELD WORKSTATION – I


    (dedicated to this product family)

    • Manual process with one operator


    • Cycle time: 39 second
    • Changeover time: 10 minutes (fixture change)
    • Machine reliability: 100%
    • Observed inventory:
    ▪ 1100 pieces of type “LH”
    ▪ 600 pieces of type “RH”

    3. SPOT WELD WORKSTATION – II


    (dedicated to this product family)
    • Manual process with one operator
    • Cycle time: 46 second
    • Changeover time: 10 minutes (fixture change)
    • Machine reliability: 80%
    • Observed inventory:
    ▪ 1600 pieces of type “LH”
    ▪ 850 pieces of type “RH”

    4. ASSEMBLY WORKSTATION – I
    (dedicated to this product family)

    • Manual process with one operator


    • Cycle time: 62 second
    • Changeover time: none
    • Machine reliability: 100%
    • Observed inventory:
    ▪ 1200 pieces of type “LH”
    ▪ 640 pieces of type “RH”

    5. ASSEMBLY WORKSTATION – II
    (dedicated to this product family)

    • Manual process with one operator


    • Cycle time: 40 second
    • Changeover time: none
    • Machine reliability: 100%
    • Observed finished goods inventory in warehouse:
    ▪ 2700 pieces of type “LH”
    ▪ 1440 pieces of type “RH”

    6. SHIPPING DEPARTMENT

    Removes parts from finished goods warehouse and stages them for
    truck shipment to customer.

    Information flow diagram is provided below.


    Questions:
    1. Draw Current State and Future State Map by using Companion Software. (Take Screen Shots
    and paste in word file)
    2. Calculate the time in seconds for all processes and the total cycle time.
    3. Identify the Value Added, Non – Value Added activities times and Waiting time Value stream
    activities. Show detail calculations for Material and Information flow in Current and Future
    State Map. (Upload Pdf File)

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