Acme Stamping Data Set

Acme Stamping Company produces several components Process Information

for vehicle assembly plants. This case concerns one All processes occur in the following order
product family, a steel instrument-panel bracket and each piece goes through all processes.
subassembly in two types: one each for left-hand
and right-hand drive versions of the same automobile 1. Stamping
model. These components are sent to the State (The press makes parts for many Acme products)
Street Vehicle Assembly Plant (the customer). - Automated 200 Ton press with coil
(automatic) material feed
Production Processes - Cycle Time: 1 second (60 pieces per minute)
• Acme’s processes for this product family involve - Changeover time: 1 hour
stamping a metal part followed by welding and (good piece to good piece)
subsequent assembly. The components are then - Machine reliability: 85%
staged & shipped to the vehicle assembly plant - Observed Inventory:
on a daily basis. - 5 days of coils before stamping
- 4,600 pieces of Type “LH” finished stampings
• Switching between Type “LH” (left-hand drive) - 2,400 pieces of Type “RH” finished stampings
and Type “RH” (right-hand drive) brackets requires
a 1 hour changeover in stamping and a 10-minute 2. Spot Weld Workstation I
fixture change in the welding processes. (dedicated to this product family)
- Manual process with one operator
• Steel coils are supplied by Michigan Steel Co. - Cycle Time: 39 seconds
Steel deliveries to Acme arrive on Tuesdays - Changeover time: 10 minutes (fixture change)
and Thursdays. - Reliability: 100 %
- Observed Inventory:
Customer Requirements - 1,100 pieces of Type “LH”
• 18,400 pieces per month - 600 pieces of Type “RH”
- 12,000 per month of Type “LH”
- 6,400 per month of Type “RH” 3. Spot Weld Workstation II
• Customer plant operates on two shifts (dedicated to this product family)
• Palletized returnable tray packaging with 20 - Manual process with one operator
brackets in a tray and up to 10 trays on a pallet. - Cycle Time: 46 seconds
The customer orders in multiples of trays. - Changeover time: 10 minutes (fixture change)
• One daily shipment to the assembly plant - Reliability: 80%
by truck. - Observed Inventory:
- 1,600 pieces of Type “LH”
Work Time - 850 pieces of Type “RH”
• 20 days in a month
• Two shift operation in all production 4. Assembly Workstation I
departments (dedicated to this product family)
• Eight (8) hours every shift, - Manual process with one operator
with overtime if necessary - Cycle Time: 62 seconds
• Two 10-minute breaks during each shift. - Changeover time: none
Manual processes stop during breaks. - Reliability: 100%
Unpaid lunch. - Observed Inventory:
- 1,200 pieces of Type “LH”
Acme Production Control Department - 640 pieces of Type “RH”
• Receives State Street’s 90/60/30-day forecasts
and enters them to MRP. 5. Assembly Workstation II
• Issues Acme 6-week forecast to Michigan (dedicated to this product family)
Steel Co. via MRP - Manual process with one operator
• Secures coil steel by weekly FAXed order - Cycle Time: 40 seconds
release to Michigan Steel Co. - Changeover time: none
• Receives daily firm order from State Street - Reliability: 100%
• Generates MRP-based weekly departmental - Observed Finished-Goods Inventory in Warehouse:
requirements based upon customer order, WIP - 2,700 pieces of Type “LH”
inventory levels, F/G inventory levels, and - 1,440 pieces of Type “RH”
anticipated scrap and downtime.
• Issues weekly build schedules to Stamping, 6. Shipping Department
Welding, and Assembly processes - Removes parts from finished goods warehouse
• Issues daily shipping schedule to Shipping and stages them for truck shipment to customer.
Department
Material Flow Icons

C/T = 45 sec.

ASSEMBLY C/O = 30 min

XYZ 3 Shifts
Corporation
2% Scrap 300 pieces
1 Day
Manufacturing Outside Supermarket
Process Sources Data Box Inventory

Mon. max. 20 pieces

+ Wed.
FIFO
Withdrawal
Truck PUSH Finished Goods First-In-First-Out
Shipment Arrow to Customer Sequence Flow

Information Flow Icons

Weekly
Schedule

Schedule Load Leveling

Manual Electronic
Information Flow Information Flow

Signal Kanban Kanban Post

Withdrawal Production
Kanban Kanban

Kanban Arriving “Go See”

in Batches Kanban Paths Scheduling

General Icons

Operator

Kaizen Buffer or
Lightning Burst Safety Stock