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The manager at Ormonde Inc. collected the value stream mapping data from the plant's most problematic manufacturing cell that fabricates parts for washing machines. This data is shown in Table 1. Using this data, calculate the current state performance of the cell and answer the following questions.

### Overall Process Attributes
- **Average demand:** 490/day
- **Batch size:** 24
- **Number of shifts per day:** 3
- **Availability:** 8 hours per shift with a 45-minute lunch break

### Process Step 1: Cutting
- **Cycle time:** 130 seconds
- **Setup time:** 4 minutes
- **Uptime:** 100%
- **Operators:** 1
- **WIP:** 450 units (before Cutting)

### Process Step 2: Bending
- **Cycle time:** 270 seconds
- **Setup time:** 6 minutes
- **Uptime:** 95%
- **Operators:** 2
- **WIP:** 550 units (before Bending)

### Process Step 3: Punching
- **Cycle time:** 150 seconds
- **Setup time:** none
- **Uptime:** 100%
- **Operators:** 1
- **WIP:** 150 units (before Punching)
- **WIP:** 900 units (after Punching)

### Supplier Information
- **One shipment of:** 2,450 units each week

### Information Flow
- **All communications with customer are electronic**
- **There is a weekly order release to Cutting**
- **All material is pushed**

Click the icon to view Table 1.

#### Part 2
**a. What is the cell's current inventory level?**
- The cell's current inventory level is 2050 parts. (Enter your response as a whole number.)

#### Part 3
**b. What is the takt time for this manufacturing cell?**
- The takt time is 2.67 minutes. (Enter your response rounded to two decimal places.)

#### Part 4
**c. What is the production lead time at each process in the manufacturing cell?**
- Complete the table (Enter your responses rounded to two decimal places.)

| Interval | Lead time (days) |
|------------------------------------|------------------|
| Before Cutting | 0.92 |
| Between Cutting and Bending | 1.12 |
| Between Bending and Punching | 0.31 |
| After Punching | 1.84 |

#### Part 5
**d. What is the total processing time of this manufacturing cell?**
- The cell's total processing time is 550 seconds. (Enter your response as a whole number.)

#### Part 6
**e. What is the capacity of this manufacturing cell?**
- The cell's capacity is ________ units. (Enter your response rounded to the nearest whole number.)

Answer :

Final answer:

The capacity of the manufacturing cell at Ormonde Inc., based on the collected value stream mapping data, is approximately 300 units per day.

Explanation:

To calculate the capacity of the manufacturing cell, we need to understand the maximum number of parts it can produce given its availability, number of shifts and the cycle time at each process.

First, figure out the total available time in one day: (8 hours/shift - 45minutes/shift) * 3 shifts/day = 22.5 hours/day = 81000 seconds.

Next, find the longest cycle time of the three processes: It's the Bending process with 270 seconds.

Therefore, the maximum capacity of the manufacturing cell can be determined by simply dividing the total available time by the longest cycle time: 81000 seconds/day / 270 seconds/unit = 300 units/day.

This implies that under current conditions, the manufacturing cell can produce up to 300 parts per day to meet demand.

Learn more about Manufacturing Capacity here:

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