Reference no: EM132308588

A mattress factory uses a multi-step process to transform raw materials into mattresses. Each line performs quality checks on their own work and fixes any defects before the output goes to the next step in the process.

Each line currently has one dedicated forklift that delivers materials (raw materials, modules, sub-assemblies, etc.) to the beginning of the line and another that transports the product from the end of the line to the beginning of the next step in the process (or to storage prior to shipping – only for the final step in the process). Each forklift can transport approximately 65 crates per hour, each crate contains 4 units (or equivalent).

In the first step of the process line, springs are welded to a bent-steel frame. The process is labor intensive, but thanks to a capital investment a few years ago, the frame line now has an average output of 380 frames per hour.

Next, the frames are surrounded by a fabric bag with built-in padding to prevent the frame from tearing the outer surface of the mattress. The frames must be inserted into the bags and sewn shut by hand because of the dexterity required. The process requires 2 personnel working together in a team. Currently, the line has 10 teams and, on average, each team can finish 40 assemblies per hour.

The bagged frames then proceed to the padding line, which uses machinery to cut and apply memory foam padding to the top of the mattress before it is transferred to two finishing lines that run in parallel.

In the finishing lines, the outer surface of the mattress and manufacturer's tags are applied.

The padding line can process 280 mattresses per hour, finishing line 1 averages 135 mattresses per hour, and finishing line 2 averages 172 per hour.

1. Generate a flow diagram for the process as it is, label the parts, and identify any bottlenecks.  

2. Suggest how you would remedy the bottleneck in the process 1) immediately and 2) with the least amount of long-term costs to the company.