Transcription of Value Stream Mapping
1 !Introduction to Mapping !Creating a Current State Map!Introduction To Lean Techniques!Creating a Future State Map!Using a Map as a basis for Tactical Implementation PlanningAGENDAV alue Stream Mapping1. What are the customer requirements2. How to apply Continuous Flow Processing3. Which process is the pacemaker4. How to control upstream processes5. What size supermarkets (shop stock) are required6. Is it sequential or fill-up pull7. Where to level production8. At what frequency will kanban be released9. What further improvements can be madeTHE 9 KEY QUESTIONS :Future State Value Stream MappingTHE 7 Process Flow.
2 Supplier to Manufacturer & Manufacturer to Driving Flow & Internal Material Lead Time & Processing TimeCreating a Future State Value Stream ControlIOXOX444 SupermarketSupermarketwith Prod CardSupermarket with Prod Card & Withdrawal cardFirst In First Out sequence flowKanban Post Inventory Pull Symbol Information System VSM SymbolsProduction ControlElectronic information flowLevel loading ProductionSignal KanbanMin & MaxManual Information flowKaizen lightening burstTruck ShipmentMon + WedPUSH arrow300 pieces 1 Day CHANGEOVERXYZ corporationOutside sourcesSequenced-Pull BallIcons for use in Future StateGo to white board and change Go to white board and change current state to future state to future the delegates to draw it with Ask the delegates to draw it with size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Assembly # 2 Assembly # 1 Spot weld # 2 Spot weld # 1 Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x Cycle time= 39 minuteChange over=10 =100%1 x 10 TCycle time= 46 minuteChange over=10 =80%1 x Cycle time= 62 minuteChange over=0 =100%1 x Cycle time= 40 minuteChange over=0 =100%1 x IIII5 days150 A124 A2II42 A16 A216 A118 A242 A16 A227 A114
3 A2 Coils r us500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ days3 days5 daysProduction Lead Time = daysProcessing time = 188 mins1 minute39 minute46 minute62 minute40 minute3 daysCurrent State MapSlug Brackets StampingCurrents State Map Date :1 x size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Assembly # 1 Assembly # 2 Spot weld # 2 Spot weld # 2 Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x Cycle time= 39 minuteChange over=10 =100%1 x 10 TCycle time= 46 minuteChange over=10 =80%1 x Cycle time= 62 minuteChange over=0 =100%1 x Cycle time= 40 minuteChange over=0 =100%1 x IIII5 days150 A124 A2II42 A16 A216 A18 A242 A16 A227 A114 A2 500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ days3 days3
4 Days5 daysProduction Lead Time = daysProcessing time = 188 minsTakt = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins x1 minute39 minute46 minute62 minute40 minuteCoils r usAdd Takt CalculationSlug Brackets StampingCurrents State Map Date :1 x DailyStamp SW 1SW 2 Assy. 1 Assy. 21 !DRAW ON FLIP CHARTW here is Continuous Flow Possible? size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Assembly # 1 Assembly # 2 Spot weld # 2 Spot weld # 2 Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x Cycle time= 39 minuteChange over=10 =100%1 x 10 TCycle time= 46 minuteChange over=10 =80%1 x Cycle time= 62 minuteChange over=0 =100%1 x Cycle time= 40 minuteChange over=0 =100%1 x IIII5 days150 A124 A2II200 A16 A216 A18 A242 A16 A227 A114 A2 500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ days3 days3
5 Days5 daysProduction Lead Time = daysProcessing time = 188 minsTakt = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins Coils r usDrawing a Future State MapSlug Brackets StampingCurrents State Map Date :1 x DailyStamp SW 1SW 2 Assy. 1 Assy. 21 min.!DRAW ON FLIP is Continuous Flow Possible? size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Assembly # 1 Assembly # 2 Spot weld # 2 Spot weld # 2 Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x Cycle time= 39 minuteChange over=10 =100%1 x 10 TCycle time= 46 minuteChange over=10 =80%1 x Cycle time= 62 minuteChange over=0 =100%1 x Cycle time= 40 minuteChange over=0 =100%1 x IIII5 days150 A124 A2II200 A16 A216 A18 A242 A16 A227 A114 A2 500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ days3 days3
6 Days5 daysProduction Lead Time = daysProcessing time = 188 minsTakt = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins Coils r usDrawing a Future State MapSlug Brackets StampingCurrents State Map Date :1 x DailyStamp SW 1SW 2 Assy. 1 Assy. 21 min.!DRAW ON FLIP is Continuous Flow Possible? size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Assembly # 1 Assembly # 2 Spot weld # 2 Spot weld # 2 Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x Cycle time= 39 minuteChange over=10 =100%1 x 10 TCycle time= 46 minuteChange over=10 =80%1 x Cycle time= 62 minuteChange over=0 =100%1 x Cycle time= 40 minuteChange over=0 =100%1 x IIII5 days150 A124 A2II200 A16 A216 A18 A242 A16 A227 A114 A2 500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ days3 days3
7 Days5 daysProduction Lead Time = daysProcessing time = 188 minsTakt = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins Coils r usDrawing a Future State MapSlug Brackets StampingCurrents State Map Date :1 x DailyxIdeal No. Of Operators= Total Work ContentTakt No. Of Operators= 187 minutes of minutes Takt= operators= 4= target of 3 Where is Continuous Flow Possible?555555(55 X 3) + 22 = 187 minutes!DRAW ON FLIP CHARTTaktCycle TimeStamp 1 1SW 2 Assy. 1 Assy. 239 230 137 222 is Continuous Flow Possible? size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Assembly # 1 Assembly # 2 Spot weld # 2 Spot weld # 2 Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x Cycle time= 39 minuteChange over=10 =100%1 x 10 TCycle time= 46 minuteChange over=10 =80%1 x Cycle time= 62 minuteChange over=0 =100%1 x Cycle time= 40 minuteChange over=0 =100%1 x IIII5 days150 A124 A2II200 A16 A216 A18 A242 A16 A227 A114 A2 500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ days3 days3
8 Days5 daysProduction Lead Time = daysProcessing time = 188 minsTakt = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins Coils r usDrawing a Future State MapSlug Brackets StampingCurrents State Map Date :1 x size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x 10 TTT= 60 minuteC/T=55 min4x I5 days500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ dayWork contentTo 55 C/OSW 2uptime2 days Weld+ = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins Target 3 OpsCoils r usDrawing a Future State MapSlug Brackets StampingCurrents State Map Date.
9 1 x size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x 10 TTT= 60 minuteC/T=55 min4x I5 days500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ dayWork contentTo 55 C/OSW 2uptime2 days 1 Weld+ = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins Target 3 OpsCoils r usDrawing a Future State MapSlug Brackets StampingCurrents State Map Date :1 x size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x 10 TTT= 60 minuteC/T=55 min4x I5 days500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ dayWork contentTo 55 C/OSW 2uptime2 days 11 Weld+ = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins Target 3 OpsDrawing a Future State MapSlug Brackets StampingCurrents State Map Date.
10 1 x size = 1320 pieces/ month 200 A1 120 A2 2 shiftsShipping Stamping Cycle time= 1 minuteChange over=1 hourUptime =85%1 x 10 TTT= 60 minuteC/T=55 min4x I5 days500 ft coilsTuesdayandThursdayProduction Planning30/ 60/ 90 day forecastDaily expedite6 week forecastWeekly faxMRPW eekly planDailyshippingplan16 pieces/ dayWork contentTo 55 C/OSW 2uptime2 days 1batchWeld+ = 2(480-20)minutes = mins16 piecesPitch = mins x 1 pieces = mins Target 3 OpsCoils r usDrawing a Futu
