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)
