Ques 1: Value Stream Map with timeline:

Batch assumption 1(Shown below): Batch is just for moving or storing; Processing time = 30 secs (based on 120/hr flow rate)
Batch assumption 2: 100 are processed as a batch at a time. Flow rate 120/hr; Processing time = (100/120) hr = 50 minutes
Affects first data box (50 mins), timeline, and total (13.625days 3405 sec; 3405 secs)

Weekly
Order
Chairvana - Current State
SteelyHollow MetalForming
Weekly Monthly
Planning forecast BigMart
Order
Weekly
Order

1x 2x
1x
Weekly Weekly
Weekly

3000 tubes 1000 tops

2500 tubes
1200 bases

Hole Leg Hinge Table Package

Punching Bending Assembly Assembly
FIFO 500 tables
2000 tubes
P/T 30 sec P/T 60 secs P/T 120 P/T 180 secs P/T 45 secs
Batch 100

Stations 2 Stations 2 Stations 3 Stations 2

2.5 days 3.125 days 3.75 days 3 days 1.25 days 13.625 days 435s

30 s 435 s
60s 120s 180s 45s
Ques 2: Takt time = (Available time/Customer demand) = 2400/2000= 1.2 minutes = 1.2 mins or 72 seconds
Available time = 5 days * 8 hrs* 60 mins = 2400 minutes
Customer demand = 2000 tables

Ques 3: Cycle Time and Utilization

Hole Punching Leg Bending Hinge Assembly Table assembly Packaging Total Process
Time Options
(for Question
#4)
Stations 1 2 2 3 2
Processing time 30 secs or 50 60 sec 120 secs 180 sec 45 sec 7min 25sec
mins (435 sec)
Batch size 1 or 100 1 1 1 1
Cycle time (if 30 secs or 50 30 secs 60 sec 60 sec 22.5 sec
based on legs) min
Cycle time (if 1 minute 1 minute 1 minute 1 minute 22.5 sec
based on tables)
Flow rate 2 tubes/min 2 tubes/min 1 base/min 1 table/min 2.667 tables/min
Demand 1.667/min 1.667/min 0.833/min 0.833/min 0.833/min
Utilization 83.33% 83.33% 83.33% 83.33% 31.25%

Ques 4:
Based on Batch assumption 1:
Total Lead time = 13.625 days and 435 seconds (109 hours and 7.25 mins)
Total Processing time = 435 seconds (7.25 minutes)

Based on Batch assumption 2:

Total Lead time = 13.625 days and 3405 seconds (109 hours and 56.75 mins)
Total Processing time = 3405 seconds (56.75 minutes)