Refer to the case study data (below) and: i) Draw the current state map for the Value Steam. [16 marks] ii) Outline the eight major questions which should be asked, and answered, when developing a future state map. Outline answers to these questions for the case study data below. [16 marks] iii) Use your answer to Q1(b)ii) to develop and draw a Future State Map, outlining the improvements made by implementing a lean manufacturing strategy in this organisation. [16 marks] Case Study Data Brompton Box Ltd produces steel components and assemblies. One particular line produces assembled water tanks for boiler manufacturer Domestiheat PLC. PART A Session: Module Title: Module Code: Page 2 of 6 January 2022 Advanced Principles in Lean Manufacturing PROD1024 DRAFT Production Processes ? The manufacturing line process involves pressing component sets from sheet steel, assembly, welding, pressure testing and packaging. ? The finished assemblies are staged and shipped to the customer each day. ? 25 rolls of steel sheet are delivered by the supplier, 2 times each month. Domestiheat’s Requirements ? 200 tanks per day. Of which: ? 100 are 60litre capacity (Nordic range) ? 80 are 40litre capacity (Mediterranean range) ? 20 are 100litre capacity (Arctic range) ? Tanks are to be shipped on pallets of 5 tanks per pallet. ? The customer orders in multiples of pallets. ? One daily shipment is sent to the customer by truck. ? Domestiheat work 3 shifts per day, 20 working days per month. Brompton Box Ltd’s Work Time ? 20 working days per month ? 2 shifts of 8 hours per day, one 30 minute meal break, and two 15 minute coffee breaks per shift. Production Control Department ? MRP system ? Customer emails demand forecast each week for the next 60 days ? Send monthly order for raw materials to supplier by email ? Customer emails daily firm order ? Issues weekly schedule to pressing, assembly, welding, pressure testing and packaging. ? Issues daily shipping schedule to despatch. Session: Module Title: Module Code: Page 3 of 6 January 2022 Advanced Principles in Lean Manufacturing PROD1024 DRAFT Session: Module Title: Module Code: Process Information The processes occur in the following sequence and each workpiece passes through all the processes. 1. Pressing ? Cycle Time = 1 second, producing all the components for one tank each cycle ? Change Over Time = 25 minutes ? Inventory in front of the process = 15 days of raw material ? Uptime = 90% ? 1 Operator 2. Assembly ? Cycle Time = 10 minutes ? Change Over Time = 20 minutes ? Inventory in front of the process = 600 Nordic, 480 Mediterranean, and 120 Arctic ? Uptime = 100% ? 2 Operators 3. Welding ? Cycle Time = 5 minutes ? Change Over Time = 10 minutes ? Inventory in front of the process = 400 Nordic, 320 Mediterranean, and 80 Arctic ? Uptime = 90% ? 2 Operator 4. Pressure Testing ? Cycle Time = 65 seconds ? Changeover Time = 2 minutes ? Inventory in front of process = 200 Nordic, 160 Mediterranean, and 40 Arctic ? Uptime = 100% ? 1 Operator 5. Packaging ? Cycle Time = 5 minutes per pallet ? Changeover Time = 30 seconds ? Inventory in front of process = 800 Nordic, 640 Mediterranean, and 160 Arctic ? Uptime = 100% ? 1 Operator Page 4 of 6 January 2022 Advanced Principles in Lean Manufacturing PROD1024 DRAFT 6. Shipping ? One shipment per day, typically of 40 pallets ? Inventory before shipping = 60 pallets of Nordic, 48 pallets of Mediterranean, and 16 pallets of Arctic.