1645014776 EX1 LEAN 2022 01 14

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Exercise 2 (12 points) The Christmas Everyday Company produces high quality professional skis for winter sport teams. The range of this product family is composed by a combination of 5 different sizes and 12 different surface painting. The customer demand is based on a combination of five different sizes and 12 surface paintings leading to 60 variants. The average demand is equal to 400 units per day, the daily demand is not so stable (+/- 25%) and everyday all the variants are requested by the customers, who are not willing to wait for the products. Production process: The production system is composed by the following stages: Machining: this stage is 50% of the time dedicated to this family product. There are two operators that use a manual machine and work in parallel on different pieces. Cutting: there are 2 operators that work in parallel in two different tables. Each operator works with manual tools and he does a ll the activities necessary to cut the item: the cutting process is composed by 6 different serial steps that take more or less the same time. A setup is necessary when product size changes; Finishing: there is one operator that uses a manual machine; a setup is necessary when product size changes; Chemical painter: there is one operator that uses an automatic machine. A setup is necessary when the variant changes. Packaging: there is an operator that uses an automatic machine. A setup is necessary when the variant changes. Each shift lasts 8 hours and there are two 15-minutes breaks per shift. All stages (except of machining stage) are completely dedicated to this product family. Upstream the production system, there is a stock of raw material of 3500 pieces. There is no scrap in any process. Stations Cycle Time (sec.) (single operator) Changeover…