INDU 6241–Lean Manufacturing

ASSIGNMENT – 2

Due back on October 24, 2022 2:45 PM.

• This is an individual assignment. Submit only your own work. Submitted files are automatically
checked for plagiarism*.

Propose an improved future state map (FSM) to transform the AEG Company problem given in
the first assignment into a lean production system. Note the following restrictions when you
develop your improved solution:

1. In general, you can assume that significant C/O times can be reduced by implementing SMED.
Other, minor C/O times can be reduced to a few seconds or eliminated altogether.
2. Value added times have already been reduced recently, so another major reduction is not
possible. They can possibly be further reduced by up to 8% through process Kaizen events
only if there is a very compelling reason to justify this reduction.
3. General guideline is to set initial operator loading to 92-95% - in this problem use 93%.
4. General guideline in an unstable environment is to have machine loading of about 80%.
5. For any other assumptions, follow the same procedures we have used in lectures.

Write a report to explain your future state solution (the material and information flow) and show
all your detailed calculations in your report by following the 8 questions in the LTS textbook.
Also, prepare a table to give a comparison of key performance indicators (total production lead
time, value added time, number of operators, etc.) between the current state and your proposed
future state solution.

Requirements
Submit the following two files on Moodle:
1. Your MS Word file of your report. Your report should also include a picture of your
FSM. Do not submit any ZIP or PDF file.
2. Your MS Visio file for your FSM (ignore the error message you get when you upload
your Visio file.) Do not submit any ZIP or PDF file.

Please Note:
Moodle will close at 2:45PM and late submissions will not be possible. Please double-check your
submitted file to make sure that you submitted the correct file before the deadline. Moodle
submissions cannot be changed after the deadline and any submissions by email cannot accepted.

*Assignments with a significant percentage of similarity score will be investigated for

plagiarism.

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