Yahoo Widgets, Inc. (YWI) is a widget manufacturer in Williamsburg, Virginia. YWI receives raw material sheets of plastic from Tribe Plastics, once per week, on Monday, for the family of widget models it produces. These widgets are then shipped to another manufacturer, Acme Gadgets, Inc. (AGI), for inclusion in its family of gadgets, which are sold to end users. For its new product line, the gadget manufacturer requires two types of widgets, large and small, that are packaged in returnable trays holding 55 widgets for shipment. The trays are returned, empty, to YWI after the widgets are used by AGI. The manufacturing process consists of a thermoforming activity that transforms the sheets of plastic into a “rough” widget, which requires a drilling process step and a grinding and sanding process step before the packing and shipping process step. These steps and related information are shown in the following table.

Questions

Using the data shown in the table above, construct a value stream map for Yahoo Widgets, Inc.

What is the takt time of the manufacturing cell?

What is the production lead time for each process step?

What is the total processing time for the manufacturing cell?

What is the total capacity of the manufacturing cell?

Process Characteristics Average Demand: 5000 per day, 3500 large, 1500 smal Batch size: 1100 Number of shifts per day: 2 Shift 8 hours with 30 minute lunch Thermo-form Process Step 1 Cycle time 15 seconds Set-up time 15 minutes Up time-85% Operators 2 Every part every week WIP 5 days of sheets in front of Thermo-forming machine Process Step 2 Dril Cycle time 32 seconds Set-up time 25 minutes Up time-8096 Operators 4 Every part every week WIP- 1250 large, 1500 small Process Step 3 Grind, Sand Cycle time 22 seconds Set-up time 27 minutes Up time 75% Operators 5 Every part every week WIP- 1750 large, 1250 small Process Step 4 Shi Information Flow Pack and Shi One shipment of 5000 per da Electronic communication of forecasts to supplier Electronic communication of daily orders from customer Electronic communication of forecasts from customer Electronic communication of daily shipping schedule to process step 4 Electronic communication of weekly schedule to process steps 1-3. All material is pushed WIP- 750 large, 125 small