Value Stream Map for NorQuest College Gift Packs Assembly Process

Activity Grading

This is an individual activity. Here, you will apply what you’ve learned about how process data is collected, analyzed, and displayed on a value stream map. You will use the detailed example outlined below. Activity Grading This activity counts for 8% of your final course grade (towards the Activities category). It is graded according to this rubric. Activity Instructions Background Information In honour of the opening of their new building, NorQuest College has prepared gift packs for each of their 20,000 students. The gift packs include (each with the college logo): A 4-subject 8.5” by 11” scribbler A pen-and-pencil set Toque, mitts, and scarf A water bottle and hot liquids container with lid A backpack to hold these items The gift packs are further distinguished by faculty, such that, of the total of 20,000 packs: 10,000 students enrolled in FCIS will receive a logoed financial calculator complete with a folded cover with a pocket for their phone and a calculator instruction booklet 10,000 HCS students will receive a special, logoed lapel watch with built-in functionality for detecting vital signs The covers of the 20,000 scribblers and backpacks will reflect the faculty in which the students were enrolled 10,000 for FCIS 10,000 for HCS The Students' Union and the purchasing department worked feverishly all spring to line up suppliers. To save money the school opted to bind the scribblers and the calculator booklets using their in-house printing and binding shop, and the students agreed to provide volunteers to cover any labour required to prepare the materials. For the printing requirements, the cycle time to assemble and bind the 8.5” x 11” scribblers is 52 seconds. The cycle time to assemble and bind the 3” x 7” calculator instruction booklets is 80 seconds. It takes about 5 minutes to set up the machine to run 120 copies of either format. Two machines are available to produce scribblers, while a third machine can be configured to run the calculator booklets. The calculators come prepackaged in individual units, in cases of 50 each. The folded covers are packed in cases of 150 each. It takes 30 seconds to dump a case of either the calculators or folded covers onto the assembly table and remove the accumulated packaging, and it takes about 30 seconds to unpack a calculator and insert it and a booklet into a cover. About 3 calculators per 1000 fail to work. The supplier has added 50 calculators to the order to be sure there are enough. Each calculator needs to be turned on to confirm it works. The pen-and pencil sets come pre-printed from the supplier in cases of 100 sets. The toques, mitts, and scarves are pre-packed in bundles of 1 toque, a right- and left-hand mitt, and a scarf, and are shipped in cartons of 25 bundles per carton. The backpacks come pre-packed in cartons of 10 backpacks, with 1 hot liquid container and 1 water bottle already in each backpack. NorQuest's new building is scheduled to be open for the fall term, and there isn’t much time to prepare the gift packs. To exacerbate this, it is expected that the calculators and special scribbler covers won’t arrive until the Friday before registration is set to begin. The printing department and the Students' Union have agreed to start packing the gift packs through the weekend before registration week, which starts on a Monday. They believe they can meet the demand with 2 days’ head start, if they work around the clock. Based on registration data pulled for previous years, the following table shows expected turnout by day and faculty over Registration Week. Registration Day FCIS HCS Monday 650 700 Tuesday 1200 1675 Wednesday 1900 3150 Thursday 3400 2250 Friday 2500 1700 These numbers are rough estimates, so the Students' Union is cautioned to produce at least 10% more than the noted numbers on any given day as not all students enroll during Registration Week. The Students' Union want to be sure that 10,000 of each type of gift pack is prepared by the last day of Registration Week. There is next to no available space for assembly of gift packs in the print room. Registration Week will take place on the main floor of the main building, in front of the Tim Horton’s, using the counter along the hall as the registration table, and the main hallway for students to queue up for registration. The students are welcome to use as much of that space between the elevators and the Tim Horton’s for assembly without interfering with either the movement of students or registration clerks on either side of the counter. Part 1: Creating Your Value Stream Create a value stream for the assembly process described above. Assuming a 2-day head start on production, working around-the-clock, calculate the task time for the process. For each step in the process, calculate The minimum practical inventory level of raw materials to store before the step The cycle time for the step The setup time for the step A practical batch size for that step The minimum number of labourers you need at each step to maintain production Assuming that all raw materials are on hand as of Friday evening, create a table showing (for the end of each day): the production total, the level of finished goods inventory for each gift pack, and the level of inventory of each raw material. Show how much lag time is available between each step without running out of gift packs at the registration counter. Identify any areas of concern on your value stream map. To meet production requirements, identify how much set-up time can you allow for each printing machine? Part 2: Submitting Your Activity When you are ready to submit a scanned copy of your activity, click on the Add submission button at the bottom of this screen. Either drag-and-drop your file to the indicated area or click on the Add... option and select the file you wish to submit. When you are ready, click on Save changes.