Improving Mixed Model Value Streams - eVSM · 2017-07-18 · Hand Exercises 161 ACME Mixed Model...

Copyright © 2015 The eVSM Group, All Rights Reserved

Improving Mixed Model

Value Streams



Lean, VSM, & eVSM 3

Working with Quick Stencils in eVSM v8 20

Plant Level Mapping 23

Discrete Parts VSM Terms 30

ACME Case Study – Plant 36

Quick Manufacturing Tutorial 49

Mixed Model Environment 125

Mixed Model Slides 126

Hand Exercises 161

ACME Mixed Model Case Study 181

ACME Case Study – Plant 182

eVSM Wizards 187

Spaghetti Wizard Tutorial 189

Standard Work Wizard Tutorial 205

Copyright © 2015 The eVSM Group, All Rights Reserved 2


Lean, VSM, & eVSM

3Lean VSM & eVSM


Cycle Time / Takt Time Chart

Se

c/It

em

0

1

2

3

4

5

6

7

8

A 040 A 060 A 080

Cycle Time Per Unit

Activity Takt Time

14

Day

Hr

5

Wk

Day

all

Customer

Customer Demand

ItemDay

7000

A 0101

ATLAS Warehouse

Activity Lead Time

Day0

A 020

Control

Activity

1

Blanks

Day1. 07

Inventory Item7500

A 030

1

Mold Handles

Min0. 47

Qty Per Cycle Item5

Cycle Time Sec28

1

A 040

1

Molded Blanks

Day0. 55

Inventory Item3850

A 050

1

Sharpen

Min0. 75

Qty Per Cycle Item5

Cycle Time Sec45

1

A 060

1

Drilled Blanks

Day0. 44

Inventory Item3100

A 070

1

Assemble

Min1

Qty Per Cycle Item10

Cycle Time Sec60

2

A 080

1

Scissors

Inventory Item9000

A 090

Activity TimeHrDay

10 Stations Stn2

Daily Order Weekly Order

1

Day0. 44

Time Summary

Takt TimeMinItem

0. 12

Total Value Added

Min2. 22

Lead Time Day2. 07

Value Added Percent

%0. 13

Z 010

Lead Time Summary

Day

0 0.2 0. 4 0. 6 0. 8 1 1. 2 1. 4 1. 6 1. 8 2 2.2

A 030

Blanks

A 050

Molded Blanks

A 070

Drilled Blanks

2. 06

Non Value Added

Legend

Value Added

U - shape Layout for Assembly Cell

Replace D 4 Drilling Station

Milling Inventory Area 5 S

New lighting in Hanger 501

Replace D 7 Drilling Station

Group Value Stream Mapping Event

Wall MapCapture

Analyze

Improve

Prioritize

eVSM / Supporting Process Improvement

5

4

3

2

1

1 2 3 4 5

Ease Of Implementation

Imp

act O

n V

alu

e

Kaizen Impact Matrix

001

002

004

003

4


Brown Paper & Post-Its

Best Practice

Maps

eVSM

Collaborative

Tools

Visio Excel

Group

Interaction

Diagramming Data

VSM Icons for Visio

Excel Integration

Application Specific Stencils

Company specificBest Practice Maps

Capture wall

maps

Use maps for

calculations

Standardized

mapping &

analysis

What is eVSM?

Applying the

standard

5Lean VSM & eVSM


eVSM Architecture

Drag and Drop Core

Visio + Excel Integration (32 bit + 64 bit)

Quick Stencils Wizards

Multi-path Maps

Kaizen Risk

Sketcher (wall maps)

Multi-level Maps

Ente

rpri

se

Pro

cess

ing

Tran

sact

ion

al

Hea

lth

care

Mu

lti-

stat

ion

Faci

lity

tim

e

Kaizen Report

Process Based Toolbar

EPEI

Man

ufa

ctu

rin

g

Kan

ban

Kaizen Impact

Production Units

Data Variation

Standard Variables

Windows 7 + 8 Support (32 bit + 64 bit)

Built-in Equations

What-If Studies

Built-in Charts

6


C/TC/OLT

Standard Variables

Design Macro Shapes

F(x)Built-inEquations

Built-in Charts

Quick Manufacturing

Lead Time

Resources

Capacity

CostOEE

-Shared Resource

-Resource Utilization

-Resource Bottlenecks

-Resource Allocation

---------------------------------

Resource Balance Chart

-Inventory Holding Cost

-Activity Based Cost

-Material Cost

-Resource Cost

-------------------------------

Cumulative Cost Chart

-VA & NVA Time

-Queues and Delays

-Process Lead Time

---------------------------

Lead Time Chart

-Cycle Time

-Multiple Stations

-Qty Per Cycle

-Takt Time

-Utilization

-Transfer Lot Size

---------------------------------------


-Scrap

-Changeover

-Setup

-Rework

-Performance

-Availability

--------------------------------

Effective Capacity Chart

Multi-Path Maps

Space Utilization

Energy Efficiency

-Map Linkage

-Side Calculations

Map Hierarchy

-Critical Path

Manufacturing Concepts

The technical concepts addressed by the Quick Manufacturing stencil are shown

below.

7Lean VSM & eVSM


What is Lean?Lean is a set of concepts, principles, and tools used to create

and deliver the most value from the customer’s perspective

while consuming the fewest resources.

...Lean Enterprise Institute

· Value is defined from the Customer’s perspective

· Map the Value Stream

· Create flow & eliminate waste

· Create pull where flow is difficult

· Seek perfection

Lean Principles

8


The Lean Process

Current State

Future State

Implementation Plan

Improvements Implementation

...Learning to See, LEI

Lean Means...· Lower cost

· Less inventory

· Less space

· Shorter lead-time

· Fewer people

9Lean VSM & eVSM


What is a Value Stream Map?A simple tool that visually represents what’s going on in a

value stream

What is a Value Stream?

All steps, both Value Added and Non Value Added, required to

complete a product or service from beginning to end

10


What is a Value Stream Map?ACME Scissors Manufacturing

Current State

Z020

Customer

7000Customer Daily Demand

Item

1

14

Day

Hr

60

Hr

Min

60

Min

Sec

1Activity Lead Time

Day

A010

ATLAS Warehouse

1

1.07 Day

Type

7500Inventory Item

A030 1

1Time

BetweenDay

A020 1

0.80 Min

1Associates Staff

10Qty Per Cycle Item

0.8Cycle Time Min

Mold Handles

A050 1

0.55 Day

Blanks

3850Inventory Item

A060 1

2.20 Min

1Associates Staff


2.2Cycle Time Min

Sharpen

A070 1

0.39 Day

Sharp Blanks

2700Inventory Item

A080 1

0.50 Min

1Associates Staff


0.5Cycle Time Min

A090 1

0.44 Day

Drilled Blanks

3100Inventory Item

A100 1

1.00 Min

1Associates Staff


1Cycle Time Min

Assemble

A110 1

1.29 Day

Scissors

9000Inventory Item

A120 1

MRP

Production

Control

Forecast 30 Days

Weekly Order

Daily

Daily

Weekly Schedule

Z010

Time Summary 1

0.12Takt Time Min

4.50Total Value

AddedMin

6.74Lead Time Day

0.08Value Added

Percent%

1

Z140

Time Summary 2

0.12Takt Time Min

6.00Total Value

AddedMin

2.64Lead Time Day

0.27Value Added

Percent%

2

1Time

BetweenDay

A150 1

2

2Stations Stn8Activity Time

Per Day Hr 9000Activity Daily

DemandItem

Drill

2

2

2


Min

0

0.02

0.04

0.06

0.08

0.1

0.12

A050

Mold Han

dles

A070

Sharpe

n

A090

Drill

A110

Assem

ble

A160

Cardb

oard

Box

es

Cycle Time Per Item

Activity Takt Time

VSM – Learning to See

11Lean VSM & eVSM


Types of Waste

Hiding the Waste

Generating

Defective

Products

Machine

Breakdowns

ReworkDelay in

DeliveryMixed

Materials

Poor

Housekeeping

Long

Set ups

Process Process Process Process

=Water

Level

Inventory

Amount

Excess Inventory

Excess MotionOver Production

Transportation

Waiting

Over Processing

Confusion

Duplicate Entry

Defects Knowledge

12


What is a LEAN Value Stream?· Define value from the customer’s perspective

· Map the value stream

· Create flow and eliminate waste

· Create pull where flow is difficult

· Seek perfection

· Minimize the LEAD TIME

· Adequate & Efficient CAPACITY

· Minimum COST for QUALITY

Lead Time, Capacity, Cost

Excess

Inventory

Waiting

Defects

Over

ProductionTransportation

Excess

Motion

Over

Processing

Capacity

Lead Time

Cost

13Lean VSM & eVSM


What is eVSM?· Software Tool:

-VSM, A3 Reports, Spaghetti Reports, Communication

Circles

-Analyze VSM Data

-Manage Lean Transformation

· Built on Visio and Excel

· Based on Publications from Lean Enterprise Institute

Lean WorkbooksProcess Level

Plant Level

Office Services

Multiple Plants

Across

Companies

Materials

14


eVSM v7 Platform

Wall Maps/Digital Pictures/eVSMValue Stream Mapping is a Paper & Pencil tool

15Lean VSM & eVSM


· Very fast way to map

· Drag, Drop & Enter Values

· Automated Calculation & Charts

What is a Quick Stencil?

Total Time=VA + NVA

=(5+1+2+5) + (10+45+15)

=13+70

=83 Min’s


Sec/I

tem

0

1

2

3

4

5

6

7

8

A040

Mol

d Han

dles

A060

Sha

rpen

A080

Ass

embl

e

Cycle Time Per Unit

Legend

Changeover Loss

Activity Takt Time


Sec/Ite

m

0

1

2

3

4

5

6

7

8

A040

Mold

Han

dles

A060

Sha

rpen

A080

Ass

emble

Cycle Time Per

UnitLegend

Scrap Loss

DownStr Loss

Activity Takt Time

Visualizing Capacity

16


Capacity LossesCycle Time / Takt Time Chart

Sec/Ite

m

0

1

2

3

4

5

6

7

8

A040

Mold

Han

dles

A060

Sharp

en

A080

Ass

emble

Cycle Time Per Unit

Legend

Changeover Loss

Activity Takt Time


Sec/Ite

m

0

1

2

3

4

5

6

7

8

A040

Mold

Han

dles

A060

Sha

rpen

A080

Ass

emble

Cycle Time Per Unit

Legend

Scrap Loss

DownStr Loss

Activity Takt Time

Visualizing Lead Time

17Lean VSM & eVSM


Visualizing Cost

Kaizen – Ideas in Context

18



Bottleneck process. Above

takt time.

1

Badly unbalanced line.

Single cell option for sharpen and

drill.

Supermarket and pull system

Quality issues on goods reaching

customer

2

3

4

5

Improvement Cycle


Sec/Ite

m

0

1

2

3

4

5

6

7

8

A040 A060 A080

Cycle Time Per Unit

Activity Takt Time

2

01

81

61

41

21

0

8

6

4

2

2 4 6 81

0

1

2

1

4

1

6

1

8

2

0

IV

I

II

III

Difficulty Of Implementation

Imp

act O

n V

alu

e


1

2

3

4

14

Day

Hr

5

Wk

Day

all

Customer

Customer Demand

ItemDay

7000

A0101

ATLAS Warehouse

Activity Lead Time

Day0

A020

Control

Activity

1

Blanks

Day1.07

Inventory Item7500

A030

1

Mold Handles

Min0.47

Qty Per Cycle Item5

Cycle Time Sec28

1

A040

1

Molded Blanks

Day0.55

Inventory Item3850

A050

1

Sharpen

Min0.75

Qty Per Cycle Item5

Cycle Time Sec45

1

A060

1

Drilled Blanks

Day0.44

Inventory Item3100

A070

1

Assemble

Min1

Qty Per Cycle Item10

Cycle Time Sec60

2

A080

1

Scissors

Inventory Item9000

A090

Activity TimeHr

Day10 Stations Stn2

Daily Order Weekly Order

1

Day0.44

Time Summary

Takt TimeMinItem

0.12

Total Value Added

Min2.22

Lead Time Day2.07

Value Added Percent

%0.13

Z010

Lead Time Summary

Day

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2

A030Blanks

A050Molded Blanks

A070Drilled Blanks

2.06

Non Value Added

Legend

Value Added

U-shape Layout for Assembly Cell

Replace D4 Drilling Station

Milling Inventory Area 5S

New lighting in Hanger 501

Replace D7 Drilling Station

Group Value Stream Mapping Event

Select Product Family

Wall SketchCapture Map

Analyze and Visualize

Brainstorm

Improvements

Prioritize

ImprovementsCreate Future

State

Plan & Implement

Improvements

Sustain improvements

Future State becomes Current State

Improvement cycle continues

5

4

3

2

1

1 2 3 4 5


Imp

act O

n V

alu

e


001

002

003

004

005

19Lean VSM & eVSM


Working with Quick Stencils in eVSM v8

Quick Stencil

Add-ons must

be glued under

existing data

shapes

Drag out the red

icons FIRST

Use the Green icons

to draw the Flow

Yellow icons

represent optional

“Add-on” calculations

Glue

3

4

5

2

eVSM Toolbar

Access each Quick Stencil using the

Open button and a corresponding

Sketch Stencil for initial map capture

and layout will open as well

1

Blue values get

calculated

automatically

Summary

calculations

Automatic

Charts

7

8

6

Process

1

Qty Per Cycle Item1

Cycle Time Minx.xx

1

A0070

MinAuto

Activity TimeHr

Dayx.xx

20


Main Stencil

For variable name help, select

any variable and use the right-

mouse button menu “Name Help”

for a description of the variable.

9

Process

1

Qty Per Cycle Item1

Cycle Time Minx.xx

1

A0080

MinAuto

21Lean VSM & eVSM


Quick Stencil – Try This:

1. Go to a new page and use the “Open” command to access the Quick Mfg stencil.

2. Which icons from the stencil must be put on the map first?

3. How do you get quick help on the icons in the stencil?

4. Drag out an Activity Center from the stencil. How do you get a quick description of the “Qty

Per Cycle” variable in the center?

5. What is the meaning of the blue “Auto” value in the Activity Center?

22


Plant Level Mapping

23Plant Level Mapping


Activity Sequence

Activity Available Time

· Available Time = Planned Production Time after breaks

· Plant Available Time = Default Available Time for all activities

· Activity Time: Overrides the Plant Available Time at an activity

· Facility Time Wizard: Allows off-page calculation of Available

Time for different shift patterns

· Sequence arrows to explicitly establish upstream/downstream

connectivity

· Rolling scrap calculation based on connectivity

· Cumulative Cost calculation based on connectivity

· Value stream path generation for multi-lane maps based on

connectivity

24


Resource Modeling

· Resources (Manpower) are now modeled explicitly within the

value stream map.

· Resources can be connected to multiple activities.

· Resource VA and NVA times can be captured to help identify

improvement areas.

· Resource cost handling.

· Bottleneck resources are identified (Resource Utilization).

· Resource usage (balancing) chart.

OEE – Overall Equipment

Effectiveness

· Availability

-Changeover, unplanned downtime, setup

· Quality

-Scrap (and rolling scrap)

· Performance

-Machine, material, or operator inefficiency



Customer Demand

Carrying Cost

· Based on Inventory Cost

Calculated using Activity Based Costing

Carry Cost Factors

-Cost of Capital

-Damage

-Obsolescence

-Shrinkage

-Insurance

· Multiple Customers

· Path-based demand

· Demand override (Activity Demand or Demand %)

-Production for other value streams

-Product family routing

-Rework situation

26


Kaizen Report, Impact & Risk

· Kaizen burst for improvement opportunities

· Association of bursts with activities

· Improvement prioritization via impact, difficulty, and risk

· Charting with impact and risk matrices

· Kaizen reporting to spreadsheet



Capacity Modeling

Capacity analysis in Quick Mfg requires consideration of both activity capacity and resource

capacity. Let’s see it works.

Activity Capacity

So let’s say that an activity has:

· Cycle Time = 5 mins

· Qty Per Cycle = 2 Item

· Activity Time = 10 Hrs/Day

· OEE = 80%

· Number of Stations = 2

Then Cycle Time Per Item

Min/Item 25.122

5

Stations ofNumber CyclePer Qty

Time Cycle

OEEItemPer Time Cycle

TimeActivity CapacityActivity

Item/Day 38418.025.1

6010

This capacity calculation assumes that a station has all of the resources it needs over its activity

time period to process items within the cycle time stated. If this is a concern, then explicit

resources can be modeled and a resource capacity calculation can be done in addition.

28


Resource Capacity

Let’s say that for a particular resource used by an activity, (could be a person or a machine) it

has the following characteristics:

· Resource Qty = 2

· Resource Time = 8 Hrs/Day

· Resource PT (Resource Process Time) = 10 Min/Item

then,

PT Resource

Qty Resource Time ResourceCapacity Resource

10

2608

Item/Day 96

So in this example, while the Activity Capacity (independent of Resource consideration) is 384

Item/Day, the resource would actually limit the capacity to 96 Item/Day.

The Quick Mfg stencil reports both the Activity Capacity and the Resource Capacity associated

with each resource used by the activity. It also handles the issue of shared resources between

activities.



For a full glossary of lean terminology, we recommend the “Lean Lexicon”.

The terminology described here is specific to discrete parts and assemblies and we propose that

you use it to “standardize” your variables on these types of maps.

Acronyms

· OEE – Overall Equipment Effectiveness

· NVA – Non-Value Added

· VA – Value-Added

· VSM – Value Stream Map

· WACT – Weighted Average Cycle Time

· WIP – Work In Process

Discrete Parts VSM Terms

30


· Takt Time: Time interval of planned production time at which the value stream needs to

produce an item to meet demand.

· Lead Time: The time it takes for an item to move between two designated points in the process.

· OEE Rate =

· OEE Availability Rate =

· OEE Quality Rate =

· OEE Performance Rate =

Plant Operating Time

Planned Production TimePlanned

Shutdown

Operating TimeLoss

Times

Net Operating TimePerformance

Loss

Fully Productive TimeQuality

Loss

Lunch, breaks,

planned

maintenance

Loss from unplanned

downtime, setups,

changeovers

Loss from machine wear, operator

inefficiency, substandard material

Product that does not meet quality

standard

Time the facility is open and available for equipment operation.

TimeproductionPlanned

timeOperating

RateePerformancRateQualityRatetyAvailabili

TimeOperatingNet

timeproductiveFully

TimeOperating

TimeOperatingNet

Facility Time Related Terms



Station 1

Cycle Time

Station 2

Qty Per

Cycle

· Stations: Number of identical stations of an activity.

Each additional station reduces the Cycle Time Per

Unit.

· Cycle Time: The time interval between a set of

items exiting an activity and the next set.

· Qty Per Cycle: The number of items produced

during one cycle at one station.

· Cycle Time Per Unit =

· Activity Time: Planned Production Time specific to an activity.

· Activity Takt Time: Takt Time specific to an activity.

· Value-Added Time: Time of those work elements that transform the product in a way that

adds value for the customer.

· Non-Value Added Time: Time of those work elements that adds Cost but no value to the

product or service as seen by the customer.

· Uptime: The percent of Activity Time that is actually available for production work after

unplanned downtime.

· Time Per Changeover: Time required to switch a station from producing one type of item to

another.

· Process Lead Time: Time from when an item enter an activity to when it leaves the activity.

Activity Time Related Terms

StationsCyclePerQty

TimeCycle

Process Lead Time

32


· Added Cost: Additional cost “put into” an item by an activity. This is an addition to

cost of any explicit resources modeled on the map (see Resource Terms).

· Cumulative Cost: The total cost put into an item to get it to a particular point in the

value stream.

Carrying Cost Terms

· Cost of Capital: This is the annual interest rate associated with borrowing money to

finance inventory.

· Inventory Damages: The percentage of inventory damaged each year.

· Insurance on Inventory: The annual insurance premium as a percent of the inventory

value.

· Inventory Obsolescence: The percentage of inventory that becomes obsolete each year.

· Inventory Shrinkage: The percentage of inventory that is “lost” each year.

· Total Carrying Cost Factors: The overall Carrying Cost factors calculated from the

detailed factors above.

· Total Annual Inventory Carry Cost: This is the annual cost associated with carrying a

value of inventory. It is calculated by multiplying the Inventory Value and the Total

Carrying Cost Factors.

Cumulative Cost Terms



Resource Terms

· Efficiency: Efficiency rating for a resource to allow for auxiliary activities (walking,

interruptions..)

· Effective Resource Time: Resource Time * Resource Qty * Efficiency

· NVA Utilization: Resource Time Used for Non Value Added Activity / Effective Resource

Time

· Resource Cost: Cost of this resource to process an item

· Resource NVA Cost: Resource cost for NVA activity per item

· Resource PT: Resource time to process an item

· Resource PT NVA: The NVA portion of the resource time to process an item

· Resource Quantity: Quantity of resource available

· Resource Query Cost: Resource cost to service queries in a time period

· Resource Rate: Cost rate for a resource

· Resource Time: Resource available time after subtracting planned breaks.

· Resource Usage: Total resource usage per period via this pipe

· Resource Usage NVA: The NVA portion of the Total resource usage per period via this pipe

· Resource Utilization: Total Time Spent / Effective Resource Time

· Resource VA Cost: Resource cost for VA activity per item

· Total Resource Cost: Cost per time period for this resource

· Total Time Spent: Total time used of this resource

· VA Utilization: Time Used for Value Added Activity / Effective Resource Time

34

Copyright © 2015 The eVSM Group, All Rights Reserved 35Plant Level Mapping


ACME Case Study – Plant

Background and Overview

ACME, founded in 1965, specializes in high-quality surgical instruments and has recently added

surgical, re-usable, double-action cutters to its catalog, retailing at $90 per set. Each set consists

of four cast pieces which are supplied by Tower Hills Foundry. At ACME, the castings are

machined, polished, and sent to the final assembly line. The metal for the springs is supplied by

Fornost Quality steelworks in steel rolls which are cut down into springs and assembled with the

castings. One casting set and one spring set makes one final Surgical Cutter. Finally, the finished

product is individually packaged for shipping.

Introduction

You will be using this case study to create a value stream map on the wall. With your group, read

through the information below then complete the exercises at the end.

The assembled cutters are sent to packaging where they are individually boxed and then stored

for shipping.

36


Value Stream Walk

Inventory

Incoming Casting Kits

Machined Kits awaiting Polishing

Polished Kits ready for Assembly

Rolls of Spring Steel

Spring sets ready for Assembly

1000

UnitsTotals

50

100

10

150

set

set

set

set

roll

Cutters ready for packaging

Boxes ready for shipping

15

1000 item

set

To capture the current state value stream, you meet the plant supervisor in the finished goods

shipping area on Monday afternoon. You learn that the plant line works 2 shifts per day, 5 days

a week. Each shift is 8 hours including a 30 min break and two 15 min breaks. Shipment quantity

to customers is 500 surgical cutters per week.

You had previously asked the supervisor to collect inventory and time metrics for the line. Here

is the inventory summary.

As you walk upstream to where the cutters are packed, you learn that Packaging has just one

part-time (4 hours per day) operator. Packaging takes 2 minutes and adds $1 to cost per cutter

set. The OEE for the packaging process is 95%.

Next you arrive at the Assembly area which is manned by 4 operators. Assembly takes 7 minutes

per set and adds $3 to the cost. The scrap rate here is 10% and the OEE is 80%.

You follow the castings supply upstream to the Polishing area which is manned by 4 operators,

takes 5 minutes, and adds $2 per set. The OEE is 95%.

The Machine shop has 2 machines dedicated to the cutters and requires two operators on each.

This operation adds $1 per set, has a scrap rate and OEE of 20% and 75% respectively. Cycle

Time for machining is 15 minutes.

You walk back to the Assembly area and make your way to the spring production room. Spring

production has three operators. The spring sets are cut and formed from rolls of spring steel.

Each roll yields 50 sets of springs. The process takes 4 hours per roll and adds $0.25 per set to

the total cost. OEE is 85% and scrap rate is 10%.




Exercises

Part A

1. Draw a wall value stream map using the template cut outs for the product showing the

customer, inventories, and processes.

2. Show the data associated with the inventory, activities, and any costs.

Part C

1. Follow the step by step tutorial on the following pages to bring the wall map into eVSM and

create the map electronically.

Part B

1. Calculate how many days of inventory you have at each point.

2. Identify useful summary metrics for the map.

3. Identify what charts would be useful to visualize the value stream and mark these up.




Quick Manufacturing Templates




Qty Per Cycle Item

Cycle Time Min

Added Cost$

ItemOEE Input

Percent%

Stations Stn

Scrap Percent %

Activity TimeHr

Day

Plant Activity

Qty Per Cycle Item

Cycle Time Min

Added Cost$

ItemOEE Input

Percent%

Stations Stn

Scrap Percent %

Activity TimeHr

Day

Plant Activity




Qty Per Cycle Item

Cycle Time Min

Added Cost$

ItemOEE Input

Percent%

Stations Stn

Scrap Percent %

Activity TimeHr

Day

Plant Activity

Qty Per Cycle Item

Cycle Time Min

Added Cost$

ItemOEE Input

Percent%

Stations Stn

Scrap Percent %

Activity TimeHr

Day

Plant Activity






This tutorial will guide you through the steps to draw the

following map using the Quick Manufacturing stencil.

Quick Manufacturing Tutorial

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

A0040

Casting Sets

Inventory Set1500

Day15.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

A0010

Spring Steel Rolls

Inventory Roll100

Day50.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

all

1

1

1

1

1

12

12

12

12

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day26.68

Value Added Percent

%0.13

Process Time Per Unit

MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day61.95

Value Added Percent

%0.48


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

OEE Input Percent

%85

Scrap Percent %10

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

49.27

Added Cost$

Item2

Cumulative Cost

$Item49.27

Added Cost

$Item0.00

Cumulative Cost

$Item

64.71

Added Cost$

Item3

Cumulative Cost

$Item71.18

Added Cost

$Item0.00

Cumulative Cost

$Item

72.18

Added Cost$

Item1

Cumulative Cost

$Item72.18

Added Cost

$Item0.00

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.01

Added Cost$

Roll0.25

Cumulative Cost

$Item6.61

Added Cost

$Item0.00

allA0160

Operator

Resource Utilization %

104.17

Resource Quantity RQ2

Resource Time

HrDay

12

Resource Rate

$Hr

20

Resource PTMinItem5 Resource PT

MinItem10

allA0170

Machine


119.05


Resource Time

HrDay

14

Resource Rate

$Hr

15

Resource PTMinItem10

all

Inventory Summary

Z0130

Total Inventory Value

$166941.

18

all

Scrap Costs

Z0030

Total Scrap Cost

$Day

1467.11




On your Desktop, click

the “Start eVSM” icon.

1

Click to enable

macros.Click “Trust all from

publisher” to avoid the

security notice in future.

3

4

If you see a message like this,

you must “Enable” macros.

2

Step 1: Start eVSM



Quick_eVSM

Learn eVSM BasicsStep 2:

Avoid re-sizing eVSM shapes. Instead

grow the drawing page when needed.

To resize the page, hold down the “Ctrl”

key, and then drag any page edge to the

required size. This method works on all

four edges of the page.

2

VSM

Save your Visio file and then

insert a new page via the right-

mouse menus on the page-tabs.

5

52


Learn eVSM Basics

Blue icons in the main stencil

represent families of shapes. Drag

out the Transport icon.

3

Use the shape’s

right-mouse menus

to turn it into a car

4

eVSM Help resources are available in the

Learn module of the toolbar. Hover over

each help button to learn what it does.

1

Zooming:

-Ctrl + Shift = Drag Zoom Options

-Whole page view in Visio 2003/2007: Ctrl + W

-Whole page view in Visio 2010/2013: Ctrl + Shift + W

6




White icons

represent Summary

Centers

Yellow icons are

additional add-on

variables to add to

Centers

**DRAG RED

SHAPES OUT

FIRST**

Green icons

represent Centers

Purple icons are the

graphs and other

charts

Quick Mfg Stencil Overview

Below is an overview of the Quick Mfg stencil shapes.



Click the Wall Map button in the

toolbar to import a wall map picture

into eVSM.

1

Using the wall map sketcher

Click the Insert Wall Map

button to browse for the

image on your computer.

2

Draw a rectangle

over any one

process box to

scale the picture.

3

Click Done

when finished.

4

Step 3:

Wall Map

56


Using the wall map sketcher

Map visibility can be

switched on/off and

transparency can be

set in this form as well.

5

Click OK to start

sketching over the

picture.

6

Delete the wall picture.

Click the Wall Map button

again to bring up the form.

7



Click the Open button.

Select Manufacturing

and click OK.

Drag out the two red

icons first. This is

very important!

3

1

Time Center

Customer Center

Enter available hours per week

here. This is actual work hours

after subtracting break time.

8

Initiate the map for Quick Manufacturing LiteStep 4:

The Manufacturing stencils will

open on the left. For this

tutorial, use the Quick Mfg LT.

2

Select the units type and

currency for the map.

4

5

Week

day

70

Week

Hr

52

Year

Week

Un

its

Open

eVSM

Data

QuickMfg

8.02.0000.

0

58


Align all new

shapes to the grid

as you drop them.

5

Enter customer

demand here.

6

Initiate the map for Quick Manufacturing Lite

Leave “Auto” fields

alone. They will be

calculated

automatically.

7

allA0010

Customer

Customer Demand

ItemWeek

500

Share % %100

Effective Demand

ItemWeek

Auto



Drag out two Units Converter

shapes from the Quick Extras

stencil and glue to the existing

Time Center.

1

Adding Custom Unit ConvertersStep 5:

Double-click the

bottom field to change

to “Item”.

2

Click the NUM button in

the toolbar.

3

Click the “New Unit”

button, type “Set”, and

click OK. Create

another unit named

“Roll” and click OK.

4

Double-click each

field to match the

appropriate units

converters.

5

5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

NUM

eVSM

Data

QuickMfg

8.02.0000.

0

60


Adding Custom Unit Converters

allA0010

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

Double-click the

units for Customer

Demand and

change the

numerator to “Set”.

6



Unit Converters Usage

· Secs/Mins, Mins/Hrs units converters are hidden

· Made visible through NUM button in the toolbar

Visibility of a unit converter

can be switched on or off.

NUM

62


· Unit families eliminate errors when changing units

· Only Time units will appear when double-clicking on Mins to change to Hrs

· If desired unit does not appear:

· Create a new unit -- OR --

· Place a units converter on map

· Use NUM button in toolbar to create the new unit

· New unit will require units converter to connect default unit to new unit

· New unit will appear in “Select Unit” window when double-click unit (family)

· If desired unit was in the NUM, add a units converter to the map

· Built-in error proofing to prevent incompatible units

NUM



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

Draw the flow Step 6:

The green shapes are called

“Centers”. Use the centers to

represent the flow.

1

If the VA and NVA timeline is

not lined up, use the “Align

Timeline” command in the

right-mouse button menu.

2

Activity Center

Inventory Center

1A0020

Type

Inventory Itemxx

DayAuto

Process

1A0030

1

SecAuto

Qty Per Cycle Item1

Cycle Time Secx.xx

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

eVSM

Data

QuickMfg

8.02.0000.

0

64


allA0010

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

Draw the flow



MinAuto

DayAuto

Disable Flying Connector

Select Timeline

Align Timeline

MinAuto

MinAuto

DayAuto

MinAuto

Working with the timeline

· Shift the entire timeline up or down, use “Select Timeline” in the right-mouse menu

· If that option doesn’t appear in the menu, make sure you have the entire VA or NVA shape

selected and try again

· “Align Timeline” function also in the right-mouse menu will create the ladder timeline for

you if the VA and NVA shapes are not correctly aligned, as shown below

66



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

1A0020

Casting Sets

Inventory Set1000

DayAuto

Machine

1A0030

2

SecAuto

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

If text does not fit, avoid re-

sizing eVSM shapes. Instead,

make the font smaller.

2

Complete the flow and enter dataStep 7:

1A0110

Machined Sets

Inventory Set50

DayAuto

Polish

1A0120

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0180

Spring Steel Rolls

Inventory Roll10

DayAuto

Machine and form

caliper springs

1A0190

3

SecAuto

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0200

Springs

Inventory Set150

DayAuto

Check to make sure

you have the

appropriate units. If

not, double-click the

unit to change it.

3

eVSM

Data

QuickMfg

8.02.0000.

0

68


allA0010

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

Complete the flow and enter data

Complete as shown

below, including

annotation, data

values, and units.

1

1A0130

Polished Sets

Inventory Set100

DayAuto

Assemble

1A0140

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0150

Cutters

Inventory Set15

DayAuto

Package

1A0160

1

SecAuto

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0170

Boxes

Inventory Set1000

DayAuto

Double-click the

operator number

on each center to

change it.

4



· Fractional units makes specifying and computing demand quantities or production times

easier

· Provides better control of data entry and display

· Fractional units changed like any other unit on map using the NUM button in the toolbar

Fractional Units

70


Non-Value Added =

Inventory / Customer

Demand

· When entering data use tab key to go to next NVU

· Non-Value Added and Value Added ladders are already glued to Activity Center

and Inventory Center, respectively

· The standard NVUs on an Activity Center are required for calculations and MUST

NOT be deleted

Input values with a default x.xx

are mandatory and require a

numeric value otherwise the map

will not solve

Data Entry Hints

1

Inventory Itemxx

DayAuto

A0010

Type

Process

1

Qty Per Cycle Item1

Cycle Time Minx.xx

1

MinAuto

A0020



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

1A0020

Casting Sets

Inventory Set1000

DayAuto

Machine

1A0030

2

SecAuto

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0110

Machined Sets

Inventory Set50

DayAuto

Polish

1A0120

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0180

Spring Steel Rolls

Inventory Roll10

DayAuto

Machine and form

caliper springs

1A0190

3

SecAuto

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0200

Springs

Inventory Set150

DayAuto

Add Arrows from Main StencilStep 8:

Glue all arrows at

both ends.

2

eVSM

Data

QuickMfg

8.02.0000.

0

72


allA0010

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

1A0130

Polished Sets

Inventory Set100

DayAuto

Assemble

1A0140

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0150

Cutters

Inventory Set15

DayAuto

Package

1A0160

1

SecAuto

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0170

Boxes

Inventory Set1000

DayAuto

Add Arrows from Main Stencil

Use the right mouse

button menu of the

arrows to turn into a

“Push” arrow.

3

Drag the arrows from the

Main stencil on the right.

1



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

1A0020

Casting Sets

Inventory Set1000

DayAuto

Machine

1A0030

2

SecAuto

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0110

Machined Sets

Inventory Set50

DayAuto

Polish

1A0120

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0180

Spring Steel Rolls

Inventory Roll10

DayAuto

Machine and form

caliper springs

1A0190

3

SecAuto

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0200

Springs

Inventory Set150

DayAuto

Step 9: Add Transport shapeseVSM

Data

QuickMfg

8.02.0000.

0

74


allA0010

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

1A0130

Polished Sets

Inventory Set100

DayAuto

Assemble

1A0140

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0150

Cutters

Inventory Set15

DayAuto

Package

1A0160

1

SecAuto

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0170

Boxes

Inventory Set1000

DayAuto

Use the right mouse button

menu to change the shape

to have “No Frame” and

switch into a “Train” icon.

2

Glue transport

shape to arrow.

1



· Transport, Transmit, and Flow Shapes now have text box framed to allow data values to be

added if needed

· If data is added to shape, an Operation Tag and Path Locator needs to be added

· To remove frame, right-click on shape and select “Frame Icon”

Frame All

Frame Icon

No Frame

Frame All

(Default)

Frame Icon No Frame

· Use Text Block tool to move text

Transport, Transmit, and Flow Shapes

76


Blue Stack Shapes

Change Shapes

By Foot

Color Flags

Computer

Database

Electronic Document

Email

Fax

Instant Message

Light Signal

Meeting

Pager

Phone

Post

Print

Sound Signal

Spreadsheet

Tube Carrier

Wall LCD

Web Form

Whiteboard

· Blue icon stack has other shapes to choose

· Right-click on shape and select desired shapes

· Use the Stack Help button in the toolbar to see complete list of shapes in a stack after

selecting a blue or green stack icon from a stencil



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

1A0020

Casting Sets

Inventory Set1000

DayAuto

Machine

1A0030

2

SecAuto

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0110

Machined Sets

Inventory Set50

DayAuto

Polish

1A0120

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0180

Spring Steel Rolls

Inventory Roll10

DayAuto

Machine and form

caliper springs

1A0190

3

SecAuto

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0200

Springs

Inventory Set150

DayAuto

Step 10: Sequence Arrows

Sequence arrows are needed for

upstream and downstream

calculations. To add them, hold down

the SHIFT key and select the green

shapes in the order shown here.

1

Click the Sequence

button.

2

Sequence

A

B

C

D

eVSM

Data

QuickMfg

8.02.0000.

0

78


allA0010

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

1A0130

Polished Sets

Inventory Set100

DayAuto

Assemble

1A0140

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0150

Cutters

Inventory Set15

DayAuto

Package

1A0160

1

SecAuto

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0170

Boxes

Inventory Set1000

DayAuto

Sequence Arrows

E

F

G

H

I

J



· Provide a means of generating tag numbers in upstream to downstream sequence (using the

AutoTag button)

· Provide a means of generating path numbers that comprehend all of the paths on the map

(using the Auto Path button)

· Are the basis for upstream/downstream calculations in the built-in eVSM equations

Sequence Arrows Sequence

Auto Path

Auto Tag

80



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

1A0020

Casting Sets

Inventory Set1000

DayAuto

Machine

1A0030

2

SecAuto

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0110

Machined Sets

Inventory Set50

DayAuto

Polish

1A0120

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0180

Spring Steel Rolls

Inventory Roll10

DayAuto

Machine and form

caliper springs

1A0190

3

SecAuto

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0200

Springs

Inventory Set150

DayAuto

A

B

C

Step 11: Sequence Path 2

For the second path, hold the SHIFT

key and select the green shapes A to

D in the order shown. Then click the

Sequence button.

2

eVSM

Data

QuickMfg

8.02.0000.

0

82


allA0010

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

1A0130

Polished Sets

Inventory Set100

DayAuto

Assemble

1A0140

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0150

Cutters

Inventory Set15

DayAuto

Package

1A0160

1

SecAuto

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

1A0170

Boxes

Inventory Set1000

DayAuto

D

The sequence arrows

are now connecting

path one.

1



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

A0040

Casting Sets

Inventory Set1000

DayAuto

Machine

A0050

2

SecAuto

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0060

Machined Sets

Inventory Set50

DayAuto

Polish

A0070

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0010

Spring Steel Rolls

Inventory Roll10

DayAuto

Machine and form

caliper springs

A0020

3

SecAuto

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0030

Springs

Inventory Set150

DayAuto

Click Auto Path to

automatically generate Path

numbers based on Sequence

arrows.

2

Click AutoTag again to re-order

the tags based on the new

sequence arrows.

3

Auto PathAuto Tag

1

1

1

1

2

2

2

Step 12: Use Auto Path to Generate Path ID’s based on Sequence ArrowseVSM

Data

QuickMfg

8.02.0000.

0

84


A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

A0080

Polished Sets

Inventory Set100

DayAuto

Assemble

A0090

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0100

Cutters

Inventory Set15

DayAuto

Package

A0110

1

SecAuto

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0120

Boxes

Inventory Set1000

DayAuto

The sequence arrows

are now connecting

path one and two.

1 Sequence arrow visibility can be

switched On/Off with the Show

Seq button. Try it.

4

These Path Locator tags are used to specify

paths. You can manually change these. You

can add new ones with copy/paste or from

the main stencil on the right. Another way to

specify paths is with Sequence arrows and

the Auto Path function.

5

Show Seq.

all

1

12

12

12

12



Path Locaters

· Path Locaters:

· Defines Path on map

· Allow filtering of specific charts and summaries on map

· There is also an “all” value for the Path Locater

· Are typically assigned using the Auto Path button and AFTER sequence arrows have been

applied

· A Path Locater designates a center as being on path AND filters all the variable

calculations for the center by the same path

Process

A00101

Path LocaterOperation Tag

86


· Operation Tags:

· Provides short name for process step

· Identifies process step to Excel for calculations

· Defines the order in which data is plotted on charts

· Operation Tags MUST be 1-alpha and 4-numeric characters (ie: A0200)

· Are typically assigned using the Auto Tag button and AFTER sequence arrows have been

applied

Operation Tags



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

A0040

Casting Sets

Inventory Set1000

DayAuto

Machine

A0050

2

SecAuto

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0060

Machined Sets

Inventory Set50

DayAuto

Polish

A0070

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0010

Spring Steel Rolls

Inventory Roll10

DayAuto

Machine and form

caliper springs

A0020

3

SecAuto

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0030

Springs

Inventory Set150

DayAuto

1

1

1

1

2

2

2

Step 13: Time Summary by Path

Double-click to

change this

path ID to 2.

2

Double-click to

change this path

ID to 1.

3

Drag out a two

Time Summary

Centers.

1

Time Summary

1

Time Summary

Z0010

Takt TimeSecItem

Auto

Total Value Added

MinAuto

Lead Time DayAuto

Value Added Percent

%Auto


SecItem

Auto

2

Time Summary

Z0150

Takt TimeSecItem

Auto

Total Value Added

MinAuto

Lead Time DayAuto

Value Added Percent

%Auto


SecItem

Auto

eVSM

Data

QuickMfg

8.02.0000.

0

88


A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

Auto

A0080

Polished Sets

Inventory Set100

DayAuto

Assemble

A0090

4

SecAuto

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0100

Cutters

Inventory Set15

DayAuto

Package

A0110

1

SecAuto

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0120

Boxes

Inventory Set1000

DayAuto

all

1

12

12

12

12

Time Summary by Path



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

56.00

Pre OEE Capacity

ItemDay

56.00

OEE Percent %100.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

168.00

Pre OEE Capacity

ItemDay

168.00

OEE Percent %100.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

175.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %100.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

29.00

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Step 14: Perform Calculations

When complete, note that

all blue values show

calculated results

3

Double-click the unit if

you would like to change

it to minutes, or any

other time measure.

4

eVSM

Data

QuickMfg

8.02.0000.

0

90


A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

120.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %100.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

420.00

Pre OEE Capacity

ItemDay

420.00

OEE Percent %100.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

Click the “Solve” button

to calculate.

2

Click the “Check” button

and fix any problems

flagged.

1

CheckSolve



First Check then Solve

· Performs comprehensive model checking

· Fixes obvious problem

· Provides list of outstanding issues

Check Button

· Performs basic model checking

· Stops if there is any obvious issues like missing data values

· Solves the built-in equations and puts the results on the map

· Exports data to an Excel spreadsheet

Solve Button

Users should first Check and then Solve the map.

Check

Solve

92



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

56.00

Pre OEE Capacity

ItemDay

56.00

OEE Percent %100.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

168.00

Pre OEE Capacity

ItemDay

168.00

OEE Percent %100.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

175.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %100.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

29.00

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Step 15:

Use the right mouse

button menu of chart icon

and select “Plot Chart”

Drag out CT/TT

Chart icon

1

2

CT / TT Chart

Add Cycle Time Takt Time Chart

CT / TT

Chart

eVSM

Data

QuickMfg

8.02.0000.

0

94


A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

120.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %100.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

420.00

Pre OEE Capacity

ItemDay

420.00

OEE Percent %100.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

Add Cycle Time Takt Time Chart Here is the chart. Note the

bottleneck in the Machine

activity.

3


Min

/Ite

m

0

2

4

6

8

10

12

14

16

A0020

Mac

hine

and

form

ca.

.

A0050

Mac

hine

A0070

Polish

A0090

Ass

emble

A0110

Pac

kage

Cycle Time Per Unit

Legend

Activity Takt Time



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

112.00

Pre OEE Capacity

ItemDay

112.00

OEE Percent %100.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

168.00

Pre OEE Capacity

ItemDay

168.00

OEE Percent %100.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

175.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %100.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Step 16: Try Add-on Calculations: Stations

Drag out the Stations

add-on and glue to the

Machine Activity Center.

1

Activity Stations

Activity Center

Run “Solve” and

note the changes in

the chart.

2

Stations Stn2

Solve

eVSM

Data

QuickMfg

8.02.0000.

0

96


A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

120.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %100.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

420.00

Pre OEE Capacity

ItemDay

420.00

OEE Percent %100.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

CT / TT

Chart

Try Add-on Calculations: Stations


Min

/Ite

m

0

1

2

3

4

5

6

7

8

9

A0020

Mac

hine

and

form

ca.

.

A0050

Mac

hine

A0070

Polish

A0090

Ass

emble

A0110

Pac

kage

Cycle Time Per Unit

Legend

Activity Takt Time



5

Week

day

70

Week

Hr

52

Year

Week

Un

its

50

Roll

Set

1

Set

Item

A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

Step 17: Try Add-on Calculations: OEE, Scrap, Activity Time

Activity Center

Activity Scrap

Activity OEE Direct

Run “Solve” and

note the changes in

the chart.

3

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Solve

Activity Time

eVSM

Data

QuickMfg

8.02.0000.

0

98


A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

CT / TT

Chart

Try Add-on Calculations: OEE, Scrap, Activity Time

Drag out the appropriate add-ons to

each center. Be sure to glue the

add-ons to the center.

1

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Double-click to

change to Hr/

Day.

2


Min

/Ite

m

0

2

4

6

8

10

12

A0020

Mac

hine

and

form

ca.

.

A0050

Mac

hine

A0070

Polish

A0090

Ass

emble

A0110

Pac

kage

Scrap Loss

Legend

DownStr Loss

OEE Remainder Loss

Cycle Time Per Unit

Activity Takt Time



A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Step 18: Hide/Show Variables

Click the Views button

in the toolbar.

1

Views

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

47.60

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

eVSM

Data

QuickMfg

8.02.0000.

0

100


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Hide/Show Variables

Now that the Added Cost and

Cumulative Cost variables are

visible, fill in the data values

for Added Cost and click the

Solve button.

4

Cumulative Cost

$Item47.60

Added Cost

$Item0.00

Cumulative Cost

$Item

57.48

Added Cost$

Item3

Cumulative Cost

$Item63.22

Added Cost

$Item0.00

Cumulative Cost

$Item

64.22

Added Cost$

Item1

Cumulative Cost

$Item64.22

Added Cost

$Item0.00

Check the Added

Cost visibility box

and click OK.

3

Check the

Cumulative Cost

visibility box.

2

Solve



A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Step 19:

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

47.60

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

Cost Chart

Make sure the fractional

units for the Added Cost

variable match. Double-

click to change it.

1

Cost Chart

Use the right mouse button

menu of chart icon and select

“Plot Chart”

Drag out the Cost

Chart from the

Quick Mfg stencil.

3

2

Cost

Chart

eVSM

Data

QuickMfg

8.02.0000.

0

102


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Cumulative Cost

$Item47.60

Added Cost

$Item0.00

Cumulative Cost

$Item

57.48

Added Cost$

Item3

Cumulative Cost

$Item63.22

Added Cost

$Item0.00

Cumulative Cost

$Item

64.22

Added Cost$

Item1

Cumulative Cost

$Item64.22

Added Cost

$Item0.00

Cost Chart

Cost Chart

$/Ite

m

0

10

20

30

40

50

60

70

A0010

Spr

ing

Ste

el R

olls

A0020

Mac

hine

and

form

ca.

.

A0030

Spr

ings

A0040

Cas

ting

Set

s

A0050

Mac

hine

A0060

Mac

hine

d Set

s

A0070

Polish

A0080

Polishe

d Set

s

A0090

Ass

emble

A0100

Cut

ters

A0110

Pac

kage

A0120

Box

es

Added Scrap Cost

Legend

Added Cost

Cumulative Cost



A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

47.60

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

Step 20: Plot Lead Time Chart

Use the right mouse

button menu of chart

icon and select “Plot

Ladder Chart”

Drag out Lead

Time Chart icon.

2

1

See how the lead times

for the two paths match

the Time Summaries

3

Lead

Time

all

Lead Time Chart

eVSM

Data

QuickMfg

8.02.0000.

0

Lead Time Summary

0 5 10 15 20

A0040

Casting Sets

A0060

Machined Sets

A0080

Polished Sets

A0100

Cutters

A0120

Boxes

21.68

A0010

Spring Steel

Rolls

A0020

Machine and

form caliper

springs

A0030

Springs

A0100

Cutters

A0120

Boxes

2

16.95

104


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Cumulative Cost

$Item47.60

Added Cost

$Item0.00

Cumulative Cost

$Item

57.48

Added Cost$

Item3

Cumulative Cost

$Item63.22

Added Cost

$Item0.00

Cumulative Cost

$Item

64.22

Added Cost$

Item1

Cumulative Cost

$Item64.22

Added Cost

$Item0.00

Plot Lead Time Chart

Lead Time SummaryDay

25

1

Non Value Added

Legend

Value Added



A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

49.27

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

Step 21: Resource Modeling

Resource PTMinItem5

Resource Center

Add Resource Pipes for the

appropriate Resource Centers to

Activity Centers. Make sure the

correct unit is changed for the

data on the Resource Pipe.

4

eVSM

Data

QuickMfg

8.02.0000.

0

106


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Cumulative Cost

$Item49.27

Added Cost

$Item0.00

Cumulative Cost

$Item

64.98

Added Cost$

Item3

Cumulative Cost

$Item71.47

Added Cost

$Item0.00

Cumulative Cost

$Item

72.47

Added Cost$

Item1

Cumulative Cost

$Item72.47

Added Cost

$Item0.00

Resource Modeling

Drag out the Resource

Center from the Quick

Mfg stencil.

1

allA0160

Operator


104.17


Resource Time

HrDay

12

Resource Rate

$Hr

20Resource PT

MinItem10

allA0170

Machine


119.05


Resource Time

HrDay

14

Resource Rate

$Hr

15


Right-click the center

to change into a

Machine.

2

To add Resource Pipes, hold down

the SHIFT key and select the

Resource Center and then the

Activity that it is being piped into, then

click the Auto Pipe button.

3

Auto Pipe

A

B



A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

49.27

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

Step 22: Resource Balance Chart

Resource PTMinItem5

Click the Solve button

to update the new

calculations.

1

Solve


Resource

Balance

Use the right mouse

button menu of chart

icon and select “Plot

Chart”

Drag out the

Resource Balance

Chart shape.

3

2

eVSM

Data

QuickMfg

8.02.0000.

0

108


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Cumulative Cost

$Item49.27

Added Cost

$Item0.00

Cumulative Cost

$Item

64.98

Added Cost$

Item3

Cumulative Cost

$Item71.47

Added Cost

$Item0.00

Cumulative Cost

$Item

72.47

Added Cost$

Item1

Cumulative Cost

$Item72.47

Added Cost

$Item0.00


allA0160

Operator


104.17


Resource Time

HrDay

12

Resource Rate

$Hr

20


allA0170

Machine


119.05


Resource Time

HrDay

14

Resource Rate

$Hr

15



Min

/Da

y

0

200

400

600

800

1000

1200

1400

1600

A0160

Ope

rato

r

A0170

Mac

hine

Polish

Assemble

Assemble

Resource Usage PT

Legend

Effective Resource Time



A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

49.27

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

Step 23: Kaizen Improvements

Resource PTMinItem5

Very high level of

Casting Set

inventory

001

Machine process

is a bottleneck

because of low

OEE

002

Right click kaizen and select “Edit

Kaizen”. Add relevant information in the

Kaizen Properties form, such as Impact

and Ease of Implementation values.

2

Kaizen

Data

eVSM

Data

QuickMfg

8.02.0000.

0

110


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Cumulative Cost

$Item49.27

Added Cost

$Item0.00

Cumulative Cost

$Item

64.98

Added Cost$

Item3

Cumulative Cost

$Item71.47

Added Cost

$Item0.00

Cumulative Cost

$Item

72.47

Added Cost$

Item1

Cumulative Cost

$Item72.47

Added Cost

$Item0.00

Kaizen Improvements

allA0160

Operator


104.17


Resource Time

HrDay

12

Resource Rate

$Hr

20


allA0170

Machine


119.05


Resource Time

HrDay

14

Resource Rate

$Hr

15


Reduce assemble

CT

003

Increase delivery

frequency to

customer

004

Drag out Kaizen

starbursts from the

Quick Extras stencil.

1

Click the Kaizen Export button

in the toolbar to create a kaizen

report in Excel.

3

Kaizen Export



A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

49.27

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

Step 24: Kaizen Impact Matrix

Resource PTMinItem5

Very high level of

Casting Set

inventory

001

Machine process

is a bottleneck

because of low

OEE

002

Kaizen

Data

eVSM

Data

QuickMfg

8.02.0000.

0

5

4

3

2

1

1 2 3 4 5


Imp

act O

n V

alu

e


001

002

003

004

112


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Cumulative Cost

$Item49.27

Added Cost

$Item0.00

Cumulative Cost

$Item

64.98

Added Cost$

Item3

Cumulative Cost

$Item71.47

Added Cost

$Item0.00

Cumulative Cost

$Item

72.47

Added Cost$

Item1

Cumulative Cost

$Item72.47

Added Cost

$Item0.00


allA0160

Operator


104.17


Resource Time

HrDay

12

Resource Rate

$Hr

20


allA0170

Machine


119.05


Resource Time

HrDay

14

Resource Rate

$Hr

15


Reduce assemble

CT

003

Increase delivery

frequency to

customer

004

Drag out the Kaizen

Impact Matrix and

right-click to plot.

1

Kaizen

Impact

Matrix



eVSM

Data

QuickMfg

7.30.0182.

2

A0040

Casting Sets

Inventory Set1000

Day10.00

Machine

A0050

2.00

Min15.00

Qty Per Cycle Set1

Cycle Time Min15

CapacityItemDay

75.04

Pre OEE Capacity

ItemDay

112.00

OEE Percent %75.00

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

142.80

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll10

Day5.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

133.00

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set150

Day1.50

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

Stations Stn2

OEE Input Percent

%75

Scrap Percent %20

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item45.60

Added Cost

$Item0.00

Cumulative Cost

$Item

49.27

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

Set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

Resource PTMinItem5

ACME Plant – Current State

114


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

96.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %80.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set1000

Day10.00

all

1

12

12

12

12

OEE Input Percent

%80

Scrap Percent %10

OEE Input Percent

%95

Activity TimeHr

Day4

Cumulative Cost

$Item49.27

Added Cost

$Item0.00

Cumulative Cost

$Item

64.98

Added Cost$

Item3

Cumulative Cost

$Item71.47

Added Cost

$Item0.00

Cumulative Cost

$Item

72.47

Added Cost$

Item1

Cumulative Cost

$Item72.47

Added Cost

$Item0.00

allA0160

Operator


104.17


Resource Time

HrDay

12

Resource Rate

$Hr

20


allA0170

Machine


119.05


Resource Time

HrDay

14

Resource Rate

$Hr

15


all

Inventory Summary

Z0130


$121782.

50

all

Scrap Costs

Z0030

Total Scrap Cost

$Day

1472.25



ACME – Resource Modeling

Exercise

With your group, read the information below and then:

1. Model the resources for the activity.

2. Show the data associated with the resource handling as well as resource pipe data.

3. Calculate the map.

4. Identify what charts would be useful to visualize the value stream and mark these up.

5. Identify where there is a bottleneck.


ACME sells Surgical Cutters which are made from a combination of springs and kits. The plant

line first creates the polished kits from the casting sets and then joins the springs in the Assemble

step. You take a second value stream walk with the plant supervisor to model the resource

allocation for the activity processes.

Value Stream Walk

The plant supervisor explains how resources are coming from technicians as well as machines.

You first notice that the Assemble activity has two different resources being piped into it. The

first is a machine that runs 14 hours a day with a resource quantity of 1 at a cost of $15 an hour.

The second resource is an operator that works 12 hours a days with a resource quantity of 2 at

$20 an hour. Both have a resource process time of 10 minutes. The operator is also shared at the

Polish activity with a resource process time of 5 minutes.

116



Multi-Station Workshop

BSQI has augmented their old machine with a new machine for making machined kits to increase

capacity.

Insert a new page and use the Open button to select the Mfg Multi Station Wizard to calculate the

equivalent capacity from the two machines as shown below.

14

Day

Hr

Un

its

50

Roll

Set

1

Set

Item

Old Machine

1A0040

Qty Per Cycle_M

set1

Cycle Time_M Min10

Cycle Time Per Item

Min10.00

Stations_M Stn1

Activity Time_M

HrDay

14

OEE Percent_M

%80

CT Capacity Per Day

Item84.00

QPC Contributor

ItSq84.00

All Stations Time

HrDay

14.00

Capacity Per Day

Item67.20

New Machine

1A0050

Qty Per Cycle_M

set1

Cycle Time_M Min20

Cycle Time Per Item

Min20.00

Stations_M Stn1

Activity Time_M

HrDay

14

OEE Percent_M

%70

CT Capacity Per Day

Item42.00

QPC Contributor

ItSq42.00

All Stations Time

HrDay

14.00

Capacity Per Day

Item29.40

Multiple Station Equiv.

1Z0060

Stations Stn2.00

MS Capacity Per Day

Item96.60

Activity TimeHr

Day14.00

MS CT Capacity Per Day Item126.00

MS Cycle Time Per Item Min6.67

OEE Percent %76.67

Qty Per Cycle set1.00

Cycle Time Min13.33

118


Improvement Workshop

Part C

1. Identify any improvements that can be made to the process.

2. Use kaizen bursts on the map, to capture and prioritize all the improvements you identified.

3. Using Map Copy as a starting point, design a future state map for ACME Surgical Cutter

production.



eVSM

Data

QuickMfg

7.30.0182.

2

A0040

Casting Sets

Inventory Set500

Day5.00

Machine

A0050

2.00

Min10.43

Qty Per Cycle Set1

Cycle Time Min10.43

CapacityItemDay

129.31

Pre OEE Capacity

ItemDay

161.07

OEE Percent %84.78

A0060

Machined Sets

Inventory Set50

Day0.50

Polish

A0070

4.00

Min5.00

Qty Per Cycle Item1

Cycle Time Min5

CapacityItemDay

151.20

Pre OEE Capacity

ItemDay

168.00

OEE Percent %95.00

A0010

Spring Steel Rolls

Inventory Roll2

Day1.00

Machine and form

caliper springs

A0020

3.00

Min240.00

Qty Per Cycle Roll1

Cycle Time Hr4

CapacityItemDay

140.88

Pre OEE Capacity

ItemDay

175.00

OEE Percent %85.00

A0030

Springs

Inventory Set100

Day1.00

1

1

1

1

2

2

2

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min24.43

Lead Time Day7.88

Value Added Percent

%0.37


MinItem

19.22

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day3.65

Value Added Percent

%8.13


MinItem

13.80

Stations Stn2

OEE Input Percent

%84.78

Scrap Percent %10

OEE Input Percent

%95

OEE Input Percent

%85

Scrap Percent %10

Cumulative Cost

$Item37.00

Added Cost

$Set37

Cumulative Cost

$Item

38.00

Added Cost$

Set1

Cumulative Cost

$Item41.80

Added Cost

$Item0.00

Cumulative Cost

$Item

45.47

Added Cost$

Item2

Cumulative Cost

$Item6.00

Added Cost

$Roll300

Cumulative Cost

$Item

6.25

Added Cost$

Set0.25

Cumulative Cost

$Item6.88

Added Cost

$Item0.00

Resource PTMinItem5

ACME Plant – Future State

Springs WIP will go

down because

Assemble no longer

a bottleneck.

120


5

Week

day

70

Week

Hr

52

Year

Week

Un

its

A0130

Customer

Customer Demand

SetWeek

500

Share % %100

Effective Demand

ItemWeek

500.00

50

Roll

Set

1

Set

Item

A0080

Polished Sets

Inventory Set100

Day1.00

Assemble

A0090

4.00

Min7.00

Qty Per Cycle Item1

Cycle Time Min7

CapacityItemDay

102.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %85.00

A0100

Cutters

Inventory Set15

Day0.15

Package

A0110

1.00

Min2.00

Qty Per Cycle Item1

Cycle Time Min2

CapacityItemDay

114.00

Pre OEE Capacity

ItemDay

120.00

OEE Percent %95.00

A0120

Boxes

Inventory Set120

Day1.20

all

1

12

12

12

12

OEE Input Percent

%85

Scrap Percent %5

OEE Input Percent

%95

Activity TimeHr

Day4

Cumulative Cost

$Item45.47

Added Cost

$Item0.00

Cumulative Cost

$Item

61.18

Added Cost$

Item3

Cumulative Cost

$Item64.23

Added Cost

$Item0.00

Cumulative Cost

$Item

65.23

Added Cost$

Item1

Cumulative Cost

$Item65.23

Added Cost

$Item0.00

allA0160

Operator


104.17


Resource Time

HrDay

12

Resource Rate

$Hr

20


allA0170

Machine


119.05


Resource Time

HrDay

14

Resource Rate

$Hr

15


all

Inventory Summary

Z0130


$35215.7

2

all

Scrap Costs

Z0030

Total Scrap Cost

$Day

748.38

Springs WIP will go

down because

Assemble no longer

a bottleneck.

Cost savings

because of

reduced Scrap.



ACME Plant – Dashboard

Current State Lead Time

Future State Lead Time

Current State Future State

1

Time Summary

Z0010

Takt TimeMinItem

8.40

Total Value Added

Min24.43

Lead Time Day7.88

Value Added Percent

%0.37


MinItem

19.22

2

Time Summary

Z0150

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day3.65

Value Added Percent

%8.13


MinItem

13.80

all

Inventory Summary

Z0130


$35150.5

7

all

Scrap Costs

Z0030

Total Scrap Cost

$Day

744.58

1

Time Summary

Z0270

Takt TimeMinItem

8.40

Total Value Added

Min29.00

Lead Time Day21.68

Value Added Percent

%0.16


MinItem

21.50

2

Time Summary

Z0280

Takt TimeMinItem

8.40

Total Value Added

Min249.00

Lead Time Day16.95

Value Added Percent

%1.75


MinItem

13.80

all

Inventory Summary

Z0290


$121441.

18

all

Scrap Costs

Z0300

Total Scrap Cost

$Day

1467.11


0 1 2 3 4 5 6 7 8

A0040

Casting Sets

A0060

Machined Sets

A0080

Polished Sets

A0100

Cutters

A0120

Boxes

1

7.88

A0010

Spring Steel

Rolls

A0020

Machine and

form caliper

springs

A0030

Springs

A0100

Cutters

A0120

Boxes

2

3.65

Non Value Added

Legend

Value Added


0 5 10 15 20 25

A0040

Casting Sets

A0060

Machined Sets

A0080

Polished Sets

A0100

Cutters

A0120

Boxes

1

21.68

A0010

Spring Steel

Rolls

A0020

Machine and

form caliper

springs

A0030

Springs

A0100

Cutters

A0120

Boxes

2

16.95

Non Value Added

Legend

Value Added

122


Current State CT/TT

Future State CT/TT


0 1 2 3 4 5 6 7 8

A0040

Casting Sets

A0060

Machined Sets

A0080

Polished Sets

A0100

Cutters

A0120

Boxes

1

7.88

A0010

Spring Steel

Rolls

A0020

Machine and

form caliper

springs

A0030

Springs

A0100

Cutters

A0120

Boxes

2

3.65

Non Value Added

Legend

Value Added


0 5 10 15 20 25

A0040

Casting Sets

A0060

Machined Sets

A0080

Polished Sets

A0100

Cutters

A0120

Boxes

1

21.68

A0010

Spring Steel

Rolls

A0020

Machine and

form caliper

springs

A0030

Springs

A0100

Cutters

A0120

Boxes

2

16.95

Non Value Added

Legend

Value Added


Min

/Ite

m

0

2

4

6

8

10

12

A0020

Mac

hine

and

form

ca.

.

A0050

Mac

hine

A0070

Polish

A0090

Ass

emble

A0110

Pac

kage

Scrap Loss

Legend

DownStr Loss

OEE Remainder Loss

Cycle Time Per Unit

Activity Takt Time


Min

/Ite

m

0

1

2

3

4

5

6

7

8

9

A0020

Mac

hine

and

form

ca.

.

A0050

Mac

hine

A0070

Polish

A0090

Ass

emble

A0110

Pac

kage

Scrap Loss

Legend

DownStr Loss

OEE Remainder Loss

Cycle Time Per Unit

Activity Takt Time




Mixed Model Environment

125Mixed Model Environment


Today’s Factories Are Often

Complex

References

· Creating Mixed Model Value Streams by Kevin Duggan

· Lots of “tailoring” for customers

· Shared resources

· Many product variations

· Workfloor spaghetti

· Optimization of resources

· Uncertain demand from day to day

· No management time frame

-“Creating Mixed Model Value Streams” by

Kevin Duggan

Mixed Model Slides

126


Mixed Model Value Streams

· Mixed Model means to produce a variety or mix of products or

product variations through the same value stream at the pull

of the customer.

-“Creating Mixed Model Value Streams” by

Kevin Duggan

Ten Guidelines for Mixed Model

1. Do you have the right product families?

2. What is the takt time at the pacemaker?

3. Can the equipment support takt time?

4. What is the interval?

5. What are the balance charts for the products?

6. How will we balance flow for the mix?

7. How will we create standard work for the mix?

8. How will we create pitch at the pacemaker?

9. How do we schedule the mix at the pacemaker?

10. How do we deal with changes in customer demand?

-“Creating Mixed Model Value Streams” by Kevin Duggan



Mixed Model Complexity

Value Stream Metrics

· “10 products, 9 to 12 operations, 15 stations, overlapping

capabilities”

· “Cycle times vary by product / operation / station / resource

combination”

· “Have to avoid needing human computers to figure out what

we need to improve”

Operations

People

Stations

Products

128


Product Lead Times

Stations Capacity

Takt TimeComplexity Losses

Cycle Time

S1 S2 Stations

Tim

e P

er

Unit

OEE Losses



Production Cost

Mixed Model Improvement

Excel

Input

Op10

1

SecAuto

Qty Per Cycle Item1

Cycle Time Secx.xx

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0010

Op15

1

SecAuto

Qty Per Cycle Item1

Cycle Time Secx.xx

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0020

Op20

1

SecAuto

Qty Per Cycle Item1

Cycle Time Secx.xx

CapacityItemDay

Auto

Pre OEE Capacity

ItemDay

Auto

OEE Percent %Auto

A0030

ProductProcessi

ng Time

(hr)

Wait

Time (hr)

%

Usage

3606DIE

SEL

3606GA

S

ProductProcessi

ng Time

(hr)

Wait

Time (hr)

%

Usage

3606DIE

SEL7.50

3606GA

S

ProductProcessi

ng Time

(hr)

Wait

Time (hr)

%

Usage

3606DIE

SEL

3606GA

S

Simple

Simulation

VSM

Usage Factors and

Charts

Improvement

Ideas

Visuals

· How can VS visualization effort be minimized AND give us

useful results?

130


Production Period Studies

· Ideal Sequence?

· Lead Times

Processing Time Studies

· Wait Times

· Lead Times

0.00

0.02

0.04

0.06

0.08

0.10

0.12

Day

Products

Production Periods

Production Time

Earliest release toproduction

Required By

0.00

0.10

0.20

0.30

0.40

0.50

0.60

Hr

Products

Production Time Components

Planned Downtime

Queue Time

Cycle Time



VSM Creation

Machine Utilization Studies

· Idle Times

· Bottlenecks

0.00

0.20

0.40

0.60

0.80

1.00

1.20

M1 P1 A1 Pa1

Hr

Station

Station Time Components

PlannedDowntime

Idle Time

Cycle Time

132


Drill Sharpen

Product Family Product Family

Q/UT Product Demand P/UT Op Use VSM Use System Use

Min Item Min % % %

55.00 A 4 1.25 100 11.11 11.11

VSM VSM

Q/UT Demand P/UT OEE Cycle Time Avail Time VSM Use System Use

Min Item/Day Min % Min Hr/Day % %

55.00 4 1.25 100 1.25 7.00 11.11 11.11

Stations Stations

I/UT Station Demand P/UT OEE Avail Time Op Use VSM Use System Use

Min Item Min % Hr/Day % % %

0 Stn1 1 5 100 7.00 100 11.11 11.11

Stn2

Capacity & Lead Time

VSM – Detail by Operation

A0010

Queue

Wait min55.00

Day0.07

Drill

A0020

1.00

Sec75.00

Qty Per Cycle Item1

Cycle Time Min1.25

CapacityItemDay

336.00

Pre OEE Capacity

ItemDay

336.00

OEE Percent %100.00

1

OEE Input Percent

%100

Stations Stn1

Activity TimeHr

Day7.00

Activity Demand

ItemDay

4.00

1


Sec/Ite

m

0

1

2

3

4

5

6

7

8

A040

Mold

Han

dles

A060

Sharp

en

A080

Ass

emble

Cycle Time Per Unit

Legend

Changeover Loss

Activity Takt Time


Sec/Ite

m

0

1

2

3

4

5

6

7

8

A040

Mold

Han

dles

A060

Sha

rpen

A080

Ass

emble

Cycle Time Per Unit

Legend

Scrap Loss

DownStr Loss

Activity Takt Time



Flowchart of Mix Model

Benefits of Approach

· Standardized mixed model approach

· Common visual process understanding

· Applicable to machining and assembly VS

· See true capacity for complex VS

· See how changes in mix, product, equipment effect through-

put & cost

· See how changes in staffing effect VS

· Help determine optimal staffing and inventory levels

· Do “what if’s” for varying demand and products

· Help manage improvement projects

134


Excel

Worksheet

Expected

Production Time

I_VS Worksheet

Expected Production Time

· From: Product entering the first station

· To: When it leaves the last station

· User input value and can be compared to simulator output

Value StreamAJ1

"C" for

Comment

Row Product

Expected

Production

Time

Value

Stream ID

Day

A 1 Scissors

Excel

WorksheetI_VS



Value Stream Untangling

Value Stream ID

· Each product type has a value

stream ID

· One map is generated per value

stream ID

· Value stream ID’s correspond to

product families

A Blade

Product Value Stream

A

A

A

Blade

Axle

Axle

A Blade

Product Value Stream

A

A

A

Blade

Axle

Axle

VSM_Axle

eVSM

Data

QuickMfg

8.01.0014.

0

Wait

Hr0.00

Wait Hr0

A0010

Op10

1.00

Hr18.00

Qty Per Cycle Item1

Cycle Time Hr18

A0020

Wait

Hr1.92

Wait Hr1.92

A0030

Op15

1.00

Hr18.40

Qty Per Cycle Item1

Cycle Time Hr18.40

A0040

Wait

Hr1.92

Wait Hr1.92

A0050

Op20

1.00

Hr13.97

Qty Per Cycle Item1

Cycle Time Hr13.97

A0060

Wait

Hr0.32

Wait Hr0.32

A0070

Op25

1.00

Hr3.87

Qty Per Cycle Item1

Cycle Time Hr3.87

A0080

Wait

Hr0.43

Wait Hr0.43

A0090

Op30

1.00

Hr5.56

Qty Per Cycle Item1

Cycle Time Hr5.56

A0100

Wait

Hr0.00

Wait Hr0

A0130

Op40

1.00

Hr3.63

Qty Per Cycle Item1

Cycle Time Hr3.63

A0140

Wait

Hr0.06

Wait Hr0.06

A0150

Op50

1.00

Hr3.51

Qty Per Cycle Item1

Cycle Time Hr3.51

A0160

Customer

Customer Demand

ItemWeek

9

Share % %100

Effective Demand

ItemWeek

9.00

A0170

5

Week

Day

52

Year

Week

12

Year

mth

Un

its

24

Day

hr

all

Time Summary

Takt TimeMinItem

800.00

Total Value Added

Hr66.94

Lead Time Day2.98

Value Added Percent

%93.50


MinItem

4016.40

Z0010

Title

DESCRIPTION

FILENAME

3600_TEST.VSD

REVISED

12/16/2014

TITLE

3600 test model

DATE

12/16/2014

Lead

Time

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1


0 0.5 1 1.5 2 2.5 3

A0020

Op10

A0030

Wait

A0040

Op15

A0050

Wait

A0060

Op20

A0080

Op25

A0090

Wait

A0100

Op30

A0140

Op40

A0160

Op50

2.98

Value Added

Legend

Non Value Added

CT / TT

Chart


Hr/

Item

0

2

4

6

8

10

12

14

16

18

20

A0020

Op1

0

A0040

Op1

5

A0060

Op2

0

A0080

Op2

5

A0100

Op3

0

A0140

Op4

0

A0160

Op5

0

Cycle Time Per Unit

Legend

Activity Takt Time

System

Use = 98%

System

Use = 2%

VSM_Blade

eVSM

Data

QuickMfg

8.01.0014.

0

Wait

Hr0.00

Wait Hr0

A0010

Op10

1.00

Hr18.00

Qty Per Cycle Item1

Cycle Time Hr18

A0020

Wait

Hr1.92

Wait Hr1.92

A0030

Op15

1.00

Hr18.40

Qty Per Cycle Item1

Cycle Time Hr18.40

A0040

Wait

Hr1.92

Wait Hr1.92

A0050

Op20

1.00

Hr13.97

Qty Per Cycle Item1

Cycle Time Hr13.97

A0060

Wait

Hr0.32

Wait Hr0.32

A0070

Op25

1.00

Hr3.87

Qty Per Cycle Item1

Cycle Time Hr3.87

A0080

Wait

Hr0.43

Wait Hr0.43

A0090

Op30

1.00

Hr5.56

Qty Per Cycle Item1

Cycle Time Hr5.56

A0100

Wait

Hr0.00

Wait Hr0

A0130

Op40

1.00

Hr3.63

Qty Per Cycle Item1

Cycle Time Hr3.63

A0140

Wait

Hr0.06

Wait Hr0.06

A0150

Op50

1.00

Hr3.51

Qty Per Cycle Item1

Cycle Time Hr3.51

A0160

Customer

Customer Demand

ItemWeek

9

Share % %100

Effective Demand

ItemWeek

9.00

A0170

5

Week

Day

52

Year

Week

12

Year

mth

Un

its

24

Day

hr

all

Time Summary

Takt TimeMinItem

800.00

Total Value Added

Hr66.94

Lead Time Day2.98

Value Added Percent

%93.50


MinItem

4016.40

Z0010

Title

DESCRIPTION

FILENAME

3600_TEST.VSD

REVISED

12/16/2014

TITLE

3600 test model

DATE

12/16/2014

Lead

Time

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1


0 0.5 1 1.5 2 2.5 3

A0020

Op10

A0030

Wait

A0040

Op15

A0050

Wait

A0060

Op20

A0080

Op25

A0090

Wait

A0100

Op30

A0140

Op40

A0160

Op50

2.98

Value Added

Legend

Non Value Added

CT / TT

Chart


Hr/

Item

0

2

4

6

8

10

12

14

16

18

20

A0020

Op1

0

A0040

Op1

5

A0060

Op2

0

A0080

Op2

5

A0100

Op3

0

A0140

Op4

0

A0160

Op5

0

Cycle Time Per Unit

Legend

Activity Takt Time

Excel

Worksheet

Excel

Worksheet

136


2 Hr2 Hr2 Hr

Value Stream Complexity

A

· Dedicated Balanced VS

· Dedicated Unbalanced VS

· Product Family VS

· Shared Resource Across VS’s

· Job Shop

Increasing

Complexity

Dedicated Balanced VS

· Single Product Type

· Equal CT at each station

· No waiting

Stn 1 Stn 2 Stn 3



1 hr4 hr0.5

hr

2 Hr2 Hr 3 Hr

Product Family VS

A

2 Hr3 Hr2 Hr

A

Dedicated Unbalanced VS

Stn 1 Stn 2 Stn 3

· Single Product Type

· Unequal CT at each station

· WIP ahead of slower station (Stn 2)

· Idle time at faster stations (Stn 1, Stn 3)

· 2 Product Types / One value stream

· C/O’s consume production time

· Unequal CTs create WIP & Idle Time

· Larger the inequality between CTs, the greater the losses

Stn 1 Stn 2 Stn 3

C/O

BC/O C/O

138


1

3

2

Shared Resources · Understanding how

much of a shared

resource is used by

each value stream

can help untangle

the value streams

Shared Resources

% of Shared

Resources

eVSM

Mix

Job Shop

Stn

Stn 4

Stn 2

Stn 3



I_Demand Worksheet

A

Floating Resources / Sequencing

Stn 1 Stn 2 Stn 3

· If we made sure that we are making at max one B at any time

and all operators float across Stn’s 1, 2, and 3 (x-trained) then

we only need 4 operators

B

"C" for

Comment

Row Job Product Job Qty Earliest Release Required By Last Operation

Item Day Day

J1 A 1 0 1

140


Job Qty

Earliest Release

Stn 54

· The # of products in a job and that stay together through each

operation

· Job Qty is 3, so once Stn 4 performs an operation on “A”, then

it performs the same operation on the other two A’s

· Works like a min lot size, you CANNOT break up a job other

than by splitting it into 2 jobs on the I_Demand sheet

Stn 4AJ5

3

Job #

Job Qty

· Job 1 has to wait to get its FIRST operation done until its

earliest release (to production) of 2 days

AJ1

Earliest Release

for Job 1 = 2 Days

Stn 54 is available

to do the FIRST

operation on “A”

Excel

Worksheet

Excel

WorksheetI_Demand

Excel

Worksheet

Excel

WorksheetI_Demand



Customer

Last Operation

Required By

Stn 5 Stn 13AJ1

· When is production for Job 1 required to complete (as

measured from Day 0)

· User input value and can be compared to simulator output

· Provides means of specifying WIP in the value stream as a

starting condition

· “Last Operation” references the operation that has been

completed for this job

AJ1

Last Operation = “Drill”

Excel

Worksheet

Excel

WorksheetI_Demand

Excel

Worksheet

Excel

WorksheetI_Demand

142


I_Stn Worksheet

Pre-Start Uptime

Stn 54AJ1

Pre-Start Uptime

= 80 Hrs

AJ2

· The first two jobs could have their next operation done by Stn

54

· Stn 54 has 80 hours of undeclared work before it can start on

the declared demand

"C" for

Comment

Row Station

Pre-Start

Uptime OEE

Hr % Time Cost CT Percent Time Cost CT Percent Time Cost CT Percent

Hr $/Hr % Hr $/Hr % Hr $/Hr %

Defaults 0 100 0 45 100 7 45 100 0 45 100

Stn1 2

Shift 1 Warmup Shift 1 Shift 1 OT

Excel

Worksheet

Excel

WorksheetI_Stn



Shift Warmup

OEE

Stn 54A

J1

· Product A requires a Drilling Op at Stn 54 with a Cycle Time of

5 min

· If the OEE of Stn 54 = 85%, then the Effective Cycle Time is

taken as:

5/0.85 = 5.88 mins

OEE = 85%Op = Drilling

CT = 5 Mins

· Time at the beginning of a shift where there may be different

productivity levels

Shift 1 Warmup Shift 1

TimeHr1

Cost$/Hr45

CT%

120

TimeHr7

Cost$/Hr45

CT%

100

Excel

Worksheet

Excel

WorksheetI_Stn

Excel

Worksheet

Excel

WorksheetI_Stn

144


Cycle Time Percent

I_Ops Worksheet

Shift 1

Cost/Hr45

Cycle Time %100

Shift 2

Cost/Hr60

Cycle Time %85

Stn 50

· For Stn 50

· Shift 1 runs with the nominal resources and achieves the

nominal cycle time

· Shift 2 runs with extra resources and is able to achieve a

faster cycle time and hence a reduced cycle time %

"C" for

Comment

Row

Station Product Operation Op SeqCycle

Time

Qty Per

Cycle

Minimum

Lot Size

Preferred

Lot Size

Minimum Post-

Op Wait Time

Manual

Time

ID ID ID # Hr Item Item Item Hr Hr

C M1 SC Red Machine 1 5 1 1 1 0 5

Excel

Worksheet

Excel

WorksheetI_Stn



Qty Per Cycle

Op Sequence

PrepareA

Mold

10 20

· Sequence of operations for a product

· “A” must go through the Op Sequence 10, 20 in that order

· Each operation name must have a unique operation sequence

number

· Number of items processed by a particular operation within a

single cycle at that station

Stn 5

Prepare A

Qty Per

Cycle = 1

Excel

Worksheet

Excel

WorksheetI_Ops

Excel

Worksheet

Excel

WorksheetI_Ops

146


Preferred Lot Size

Job Qty & Preferred Lot Size

Stn 54

· Preferred product lot size for an operation on a station

· Simulator accommodates by allowing same products to jump

the queue

· Contingent on input materials availability

AJ9

AJ5

AJ1

· Run Job 1: Ran 8 of A

· Run Job 3: Ran 8 (16 total) of A

· Run Job 2: Ran 5 of B

1

2

3

4

5

Job Product Job Qty

A

B

A

B

A

8

5

8

5

8

Stn 42

Drilling

Qty Per Cycle = 1

Preferred Lot Size = 10 for A

Preferred Lot Size = 5 for B

A8

Excel

Worksheet

Excel

WorksheetI_Ops

Excel

Worksheet

Excel

WorksheetI_Ops / I_Demand



Manual Time

Minimum Post Op Wait Time

Stn 54 Stn 56

Stn 5

Drilling

AJ1

· A must wait a minimum 30 mins from exiting Stn 54 and before

entering Stn 56

· Used to model transfer times

10 Mins 30 Mins 42 Mins

· If desired Cycle Time for Drilling is the same for products A

and B = 10 hrs

· BUT: A needs 20 hrs of labor (Manual Time) and B needs only

10 hrs of labor

· THEN: We need a minimum 2 people on Stn 5 when

processing A and one person when processing B

AJ1

BJ1

Excel

Worksheet

Excel

WorksheetI_Ops

Excel

Worksheet

Excel

WorksheetI_Ops

148


I_Assy Worksheet

Assembly

· Run Job 1: Ran 8 of A

· Run Job 3: Ran 8 (16 total) of A

· Run Job 2: Ran 5 of B

Assemble ScissorsA

J1

A2

A1A1

"C" for Comment

RowProduct Operation

ID ID ID Qty Per Item ID Qty Per Item

C SC Red Machine Comp A 2 Comp B 1

Component A Component B

Excel

Worksheet

Excel

WorksheetI_Assy



Alternatives and Tracks

I_Tracks & Alts

PrepareAJ1

· “A” is produced via First or Second Track

· Actual track selected during simulation based on preference

(First Only, Second Only, First If Available, Second If

Available)

Machine

Mold Sharpen

AssembleFirst Track

Second Track

"C" for Comment

Row Track ID Operation Operation

C T001 Machine Polish

Excel

Worksheet

Excel

WorksheetI_Tracks / I_Alts

150


45 Mins

Stn 3

Milling A

I_CO Worksheet

Changeover

Stn 3

Cut B

· Time and cost to go from product to product and operation to

operation at a particular station

· 45 Mins to have Station 3 ready to “cut” products of type “B”

when it is currently setup for “Milling” products of type “A”

"C" for

Comment

Row

StationFrom

Product

From

Operation

Changeover

Time

Changeover

CostTo Product To Operation

Hr $ / CO

C M1 SC Red Machine 0.2 30 SC Blue Machine

Excel

Worksheet

Excel

WorksheetI_CO



S_Make – Virtual Factory

Sim_Stations

Pro

du

ct

Exp

ecte

d P

rod

uct

ion

Tim

e

Val

ue

Stre

am ID

Op

Nam

e

Op

Seq

uen

ce

ALT

:ID

ALT

:PR

EF

ALT

:TR

AC

K

Co

mp

ID

Co

mp

Qty

Wo

rkst

atio

n

Qty

Per

Cyc

le

Min

imu

m L

ot

Size

Pre

ferr

ed L

ot

Size

Min

Wai

t Ti

me

Pre

-Sta

rt U

pti

me

OEE

Shif

t

Shif

t D

ura

tio

n

Cyc

le T

ime

Man

ual

Tim

e

Co

st R

ate

Day Per Item Item Item Item Hr Hr % Hr Hr Hr $/Hr

A 1 Scissors

Drill1 1

Stn1 1 1 1 0 2 100

Shift 1 7 2 0 45

Stn2 1 1 1 0 4 100

Shift 1 7 3 0 45

Sharpen 2

Stn3 1 1 1 0 8 100

Shift 1 7 4 0 45

Station

Pre-Start

Uptime P/UT P/PDT I/UT I/PDT Start Day

Start

Time End Day

End

Time

ID Hr Hr Hr Hr Hr Day Hr Day Hr

Stn1 2 4 0 0 0 0 2 1 0 P/UT P/UT I/UT I/PDT

Stn1 -1 - Initial ProcessingJ1 - A

Stn1 Drill1 Drill1

Stn1 120 120 180 1020

Stn1 0.00

152


1.5 Hr

Idle for 1 Hr

4 Hr

Stn 3

Drilling BJ2

P/UT

P/PDT

· A station’s processing time (P) during uptime (UT)

· P/UT = 5.5 Hrs above

Stn 3

Milling CJ1

2 Hrs

Planned downtime

(PDT) = 3 Hrs

4 Hrs

Stn 1

Milling B

Stn 1

Milling B

· Product is in-station during planned downtime

· Product B starts, is stopped during planned downtime, and

then resumes

· P/PDT = 3 Hrs

Excel

Worksheet

Excel

WorksheetSim_Stations

Excel

Worksheet

Excel




I/PDT

· Idle time (I) at a station during planned downtime (PDT)

2 Hrs

Stn 2

Milling B

Stn 3

Cutting A

I/UT

· Idle time (I) at station during uptime (UT)

· Stn 3 just finished Cutting Product A and has an idle time of 2

hrs until the next job

2 Hrs

Stn 2

Milling B

Stn 3

Cutting A

Excel

Worksheet

Excel


Excel

Worksheet

Excel


154


Sim_Products Worksheet

Q/UT

Stn 2 Stn 4

· Queue time (Q) of a product during uptime (UT)

· The Queue time during uptime of Job 1 is 2 Hrs

BJ1

30 Mins 90 Mins

Excel

Worksheet

Excel

WorksheetSim_Products

Job Product Job Qty

Started

After Op

Earliest

Release

Require

d By P/UT P/PDT Q/UT Q/PDT Start Day

Start

Time End Day

End

Time

ID ID Item Day Day Hr Hr Hr Hr Day Hr Day Hr

J1 A 1 0 1 6 0 21 0 0 2 1 5 P/UT Q/UT P/UT

J1 Stn1 Stn3

J1 Drill1 Sharpen

J1 120 1260 240

J1 0.00



Summary

Product Summary

Product Demand P/UT Q/UT VSM Use On Time System Use

Item Hr Hr % % %

A 1 6.00 21.00 100.00 0.00 100.00

VSM Summary

Demand P/UT Q/UT Activity TimeSystem Use

Item/Day Hr Hr Hr/Day %

1 0.10 0.35 2.72 100.00

Station Summary

Station Demand Sum (P/UT)Sum (I/UT)VSM Use UtilizationSystem Use

Item Hr Hr % % %

Stn1 1.00 2 0.00 33.33 57.14 33.33

Stn2 0.00 0 0.00 0.00 57.14 0.00

Stn3 1.00 4 0.00 66.67 100 66.67

Sim_VSM Worksheet

Q/PDT

Stn 2 Stn 4

· Queue time (Q) during planned downtime (PDT)

BJ1

Excel

Worksheet

Excel

WorksheetSim_Products

Sharpen Summary

Product Family Product Summary


Min Item Min % % %

0.00 A 1 240.00 100 66.67 66.67

VSM VSM Summary

Q/UT Demand P/UT OEE Cycle TimeAvail TimeVSM Use System Use


0.00 1 240.00 100 240.00 2.33 66.67 66.67

Stations Station Summary

I/UT Station Demand P/UT OEE Avail TimeOp Use VSM Use System Use


Stn1

Stn2

0 Stn3 1 240 100 2.33 100 66.67 66.67

156


Product Family

Stations

· Op Use: % of this operation’s P/UT hrs used for this product

type

· VSM Use: % of the value stream’s P/UT hrs used for this

product type

· System Use: % of the system (all value streams) P/UT hrs

used for this product type

· Op Use: % of this operation’s P/UT hrs supplied by this station

· VSM Use: % of the value stream’s P/UT hrs supplied by this

station for this operation

· System Use: % of the system (all value streams) P/UT hrs

supplied by this station for this operation

Product Family Product Summary


Min Item Min % % %

0.00 A 1 240.00 100 66.67 66.67

Stations Station Summary

I/UT Station Demand P/UT OEE Avail TimeOp Use VSM Use System Use


Stn1

Stn2

0 Stn3 1 240 100 2.33 100 66.67 66.67

Excel

Worksheet

Excel

WorksheetSim_VSM

Excel

Worksheet

Excel

WorksheetSim_VSM



Product Summary

· On Time %: % of products that are predicted to be complete

ahead of user specified “Required By” time

VSM

· Q/UT: Average wait time for a product ahead of this operation

· Post WIP: Average WIP after this operation

· P/UT: Average processing time for products at this operation

· VSM Use: P/UT hrs used at this operation as a percent of P/

UT hrs used by the value stream

Product Summary

Product Demand P/UT Q/UT VSM Use On Time System Use

Item Hr Hr % % %

A 1 6.00 21.00 100.00 0.00 100.00

VSM VSM Summary

Q/UT Demand P/UT OEE Cycle TimeAvail TimeVSM Use System Use


0.00 1 240.00 100 240.00 2.33 66.67 66.67

Excel

Worksheet

Excel

WorksheetSim_VSM

Excel

Worksheet

Excel

WorksheetSim_VSM

158


VSM Summary

Stations Summary

· Demand: Overall value stream demand

· P/UT: Average processing time per product for the value

stream

· Q/UT: Average wait time per product for the value stream

Station Summary

Station Demand Sum (P/UT)Sum (I/UT)VSM Use UtilizationSystem Use

Item Hr Hr % % %

Stn1 1.00 2 0.00 33.33 57.14 33.33

Stn2 0.00 0 0.00 0.00 57.14 0.00

Stn3 1.00 4 0.00 66.67 100 66.67

VSM Summary

Demand P/UT Q/UT Activity TimeSystem Use

Item/Day Hr Hr Hr/Day %

1 0.10 0.35 2.72 100.00

Excel

Worksheet

Excel

WorksheetSim_VSM

Excel

Worksheet

Excel

WorksheetSim_VSM




Operation

Station

A50

J1

The following exercises will make you familiar with the terms and

calculations in using the mixed model capability in eVSM.

Hand Exercises

Job Quantity

Job Quantity

Product



Drill

1. Product / Station / Operation / Op Sequence /

Job ID /Job Qty

Q1 : What are the Product names?

Q2 : What are the Job names?

Stn 1

ABJ2 Sharpen

Stn 2

5025

J1

Q3 : What are the Job Qtys associated with the two Jobs?

Q4 : What are the stations?

Q5 : What are the operations?

Q6 : What are reasonable operation sequence numbers to assign to the two operations?

162


Drill

CT= 5 Mins

2. Product: Processing, Production & Wait Time

Q1 : How long will it take to complete Job 4?

Q2 : What is the production time (Lead Time) for AJ4?

Q3 : What is the wait time for AJ4?

Stn 1

Sharpen

Stn 2

CT= 10 Mins

A A AJ1J2J3

AJ4



3. Station Selection

Drill

Stn 1

CT= 5 Mins

Sharpen

Stn 2

CT= 10 Mins

Sharpen

Stn 3

CT= 15 Mins

A A

Q1 : What is the minimum processing time for AJ1?

Q2 : What is the minimum processing time for AJ2?

J1J2

164


Drill

CTA= 10 Mins

CTB= 20 Mins

4. Station: Processing Time, Idle Time

Q1 : What are the processing times for Stn 1 and Stn 2?

Q2 : What is the idle time for Stn 2?

Stn 1

Sharpen

Stn 2

AB

CTA= 5 Mins

CTB= 5 Mins

J1J2



Drill

CTA= 2 Hrs

CTB= 4 Hrs

5. Product: Earliest Release, Start, End, &

Production Times

Q1 : What are the Production Times for A and B?

Q2 : What are the Start and End Times for A and B?

Stn 1

AB

Earliest

Release

= 2 Day

Earliest

Release

= 0 Day

J1J2

166


Drill

Stn 1

A: Min Lot Size = 1

B: Min Lot Size = 1

CT = 5 Mins

6. Product / Operation / Station: Min Lot Size

Q1 : In what sequence will jobs exit Stn 2?

Sharpen

Stn 2

A: Min Lot Size = 10

B: Min Lot Size = 3

CT = 10 Mins

A5

J1

B3

J2

B3

J3

A5

J4



Drill

7. Product / Station / Operation: Preferred Lot Size

Q1 : Would B be processed at all?

Q2 : What Qty of A would be made at the Drill Operation before starting to B?

Stn 1

ABJ2

Sharpen

Stn 2

510

J1A

J3

5

A: Preferred Lot Size = 2

(Drill, Stn 1)

B: Preferred Lot Size = 12

(Drill, Stn 1)

168


Drill

8. Station: Pre-Start Uptime

Q1 : What route will J1 take?

Q2 : What will J1's Processing Time be?

Stn 1

A Sharpen

Stn 3

J1

Stn 1: Pre-Start Uptime = 2 Hrs



Drill

Stn 2

CT = 2 Hrs

CT = 4 Hrs

Q3 : What will J1's Wait Time be?

CT = 3 Hrs



Drill

9. Available Time

Q1 : What is the station’s Available Time for Drill and Sharpen each day?

Stn 1

Sharpen

Stn 1

Stn 1 is used for both “Drill” and “Sharpen”. It spends about 50% of its time on each. If the

station runs 1 shift, 8 hours, then:

170


Drill

10. Activity Time

Q1 : What’s the total time available for the Drilling operation?

Q2 : How many stations can do drilling?

Stn 1

Drill

Stn 2

Available Time = 4

hrs/day

Available Time = 6

hrs/day



11. Activity Demand

Q1 : Both A and B belong to the Scissors value stream. What is the daily demand for this value

stream?

Demand

A

Required By (Day)

20

B 40

1

2

Product

172


Drill

Stn 1

AJ1

CT = 8 Min

OEE = 80%

12. OEE

Q1 : What is the processing time for A at the Drill operation?



Drill

Stn 1

AJ1

CT = 5 Mins

Min Wait Time = 60 Mins

13. Minimum Wait Time

Q1 : How long does J1 wait after “Drill” and before any next operation?

Sharpen

Stn 2

CT = 10 Mins

Q2 : What is the production time for J1?

174


Drill

Stn 1

AJ1

CT = 5 Mins

Manual Time = 10 Mins

14. Manual Time

Q1 : How many people are required to complete the “Drill” and “Sharpen” operations in their

“Cycle Time”?

Sharpen

Stn 2

CT = 10 Mins

Manual Time = 10 Mins



Drill

Stn 1

CT = 5 Mins

15. WIP

Q1 : What is the “Last Operation” that J1 went through?

Sharpen

Stn 2

CT = 10 Mins

A2

J2A

4

J1

Q2 : When will J1 be complete?

Q3 : When will J2 be complete?

176


Drill

Stn 1

CTA = 10

CTB = 10

16. VSM Generation

Q1 : What percent of time will be used to process A as opposed to B at each of the two stations?

Sharpen

Stn 2

A10

J1

B20

J2

A10

J3

Q2 : What’s the daily demand for A and B?

Q3 : Extract and draw a VSM for the scissors value stream.

CTA = 5

CTB = 10

VS ID = Scissors

VS ID = Shears

Required in 1 Day

2 Shifts / 10 Hrs per shift



Enter the values for the I_VS

worksheet. Note that entering a

“C” in the Comment Row will

ensure that row will not be used

for any computations

2

Station: Processing Time, Idle Time

Enter the values for

the I_Demand

worksheet

3

Enter the values for the I_Stn

worksheet. Verify the default

values for each category.

4

Click the Open button in the

eVSM Mix toolbar to open a

blank Mix template

1

Open

"C" for

Comment

Row Product

Expected

Production

Time

Value

Stream ID

Day

A 1 Scissors

B 1 Scissors

End Data

"C" for

Comment

Row Station

Pre-Start

Uptime OEE

Hr % Time Cost CT Percent Time Cost CT Percent

Hr $/Hr % Hr $/Hr %

Defaults 0 100 0 45 100 7 45 100

Stn1

Stn2

End Data

Shift 1 Warmup Shift 1

"C" for

Comment

Row Job Product Job Qty Earliest Release Required By Last Operation

Item Day Day

J1 A 1 0 0.5

J2 B 1 0 0.5

End Data

178


Enter the values for the I_Ops

worksheet. Make sure to change

the units for “Manual Time” to Min.

5

Click the Check button in the

eVSM Mix toolbar and fix any

errors flagged

6

Check

This will create the

“S_Make” worksheet

7

"C" for

Comment

Row


Time

Qty Per

Cycle

Minimum

Lot Size

Preferred

Lot Size

Minimum Post-

Op Wait TimeManual Time

ID ID ID # Min Item Item Item Hr Min

Stn1 A Drill 1 10 1 0 5

Stn2 A Sharpen 2 5 1 0 5

Stn1 B Drill 1 20 1 0 5

Stn2 B Sharpen 2 5 1 0 5

End Data

Pro

du

ct

Exp

ecte

d P

rod

uct

ion

Tim

e

Val

ue

Stre

am ID

Op

Nam

e

Op

Seq

uen

ce

ALT

:ID

ALT

:PR

EF

ALT

:TR

AC

K

Co

mp

ID

Co

mp

Qty

Wo

rkst

atio

n

Qty

Per

Cyc

le

Min

imu

m L

ot

Size

Pre

ferr

ed L

ot

Size

Min

Wai

t Ti

me

Pre

-Sta

rt U

pti

me

OEE

Shif

t

Shif

t D

ura

tio

n

Cyc

le T

ime

Man

ual

Tim

e

Co

st R

ate

Day Per Item Item Item Item Hr Hr % Hr Min Min $/Hr

A 1 Scissors

Drill 1

Stn1 1 0 0 100

Shift 1 7 10 5 45

Sharpen 2

Stn2 1 0 0 100

Shift 1 7 5 5 45

B 1 Scissors

Drill 1

Stn1 1 0 0 100

Shift 1 7 20 5 45

Sharpen 2

Stn2 1 0 0 100

Shift 1 7 5 5 45



Using eVSM Mix

Opens a blank Excel template for inputting your data.

Checks input data for any errors and flags them before simulation can run.

Runs the simulation of the input data and creates output sheets in the Excel file.

Views a summary after the simulation has run for each operation and total summary for

the value stream.

Creates a production schedule for the various products entered.

View production time components.

View station time components.

Generate value stream map by value stream ID.

Floor layout showing summary output from simulation run.

180


ACME Mixed Model Case Study

181ACME Mixed Model Case Study


ACME Case Study – Plant

Introduction

You will be using this case study to create a mixed model value stream map. Read through the

information below then complete the exercises at the end.


ACME, founded in 1965, specializes in high-quality surgical instruments and has recently added

a family of surgical, re-usable, double-action cutters to its catalog. Each set consists of four cast

pieces which are supplied by Tower Hills Foundry. At ACME, the castings are machined,

polished, and sent to the final assembly line. Differences in size and finish exist between

different cutter types in the family. The metal for the cutter springs is supplied by Fornost

Quality steelworks in steel rolls which are cut down into springs and assembled with the castings.

One casting set and one spring set makes one final Surgical Cutter. The finished product is

individually packaged for shipping to a distributor.

Product Family

The cutters product family includes three variations:

Part# CLP01SR

Size: Small

Part# CLP02MY

Size: Medium

Part# CLP03LB

Size: Large

182


Assemble

(ASSM01)

Package

(PACK01)

Machine

(MACH01)

Polish

(PLSH01)

Springs

&

Screws

Product Manufacturing Flow

Job Order List

Stations

The “Earliest Release” time is 0 days

and the “Required By” time is 3 days.

VSM

Product

CLP01SR

CLP02MY

CLP03LB

There is one operator per station and the manual time is the same as the cycle time.

Job # Product Job Qty

J1 CLP01SR 36

J2 CLP02MY 12

J3 CLP03LB 12

J4 CLP01SR 36

J5 CLP02MY 12

J6 CLP03LB 12


Time

Qty Per

Cycle

Minimum

Lot Size

Preferred

Lot Size

Minimum Post-

Op Wait Time

Manual

Time

ID ID ID # Min Item Item Item Hr Min

M1 SC Red Machine 1 5 1 1 1 0 5

MACH01 CLP01SR Machine 10 7 1 12 1 0 7

MACH01 CLP02MY Machine 10 10 1 12 1 0 10

MACH01 CLP03LB Machine 10 15 1 12 1 0 15

PLSH01 CLP01SR Polish 20 4 1 12 1 0 4

PLSH01 CLP02MY Polish 20 5 1 12 1 0 5

PLSH01 CLP03LB Polish 20 6 1 12 1 0 6

ASSM01 CLP01SR Assembly 30 8 1 12 1 0 8

ASSM01 CLP02MY Assembly 30 14 1 12 1 0 14

ASSM01 CLP03LB Assembly 30 20 1 12 1 0 20

PACK01 CLP01SR Packing 40 3 1 36 1 0 3

PACK01 CLP02MY Packing 40 5 1 24 1 0 5

PACK01 CLP03LB Packing 40 7 1 24 1 0 7



Facility Time

Facility runs 5 days a week, 2 shifts per day, 7 production hours per shift. Labor rate runs at $45

per man-hour. Each station has an OEE of 80%.

Exercises

1. Create an eVSM Mix spreadsheet for the above.

2. Confirm that the Production Time for job J6 is 2.25 days.

3. Create a value stream map.

4. We have decided to remove the large cutters (CLP03LB) from this product family. Update the

spreadsheet to reflect this and draw a new value stream.

5. Create a spaghetti diagram showing the main material flows on a “layout” page in your eVSM

Visio file. Display the simulation results on the layout.

6. If the demand doubles, how much time will be needed (no change in resources) to complete

production?

7. Which station has the longest wait time?

8. To balance the line better, we have found ways to improve performance at the Assemble

operation. All cycle times there are reduced by 50%. How does this impact the production

time?

184


1. Create a new page and name it “Layout”

2. Turn it into a background page

3. Insert picture of floorplan

4. Open Spaghetti Wizard

5. Set up Spaghetti Scale

6. Drop a Spaghetti Place icon for each machine in the VS. Use the Machine ID for each name.

7. Click the “Layout” button in the eVSM Mix toolbar

Layout




eVSM Wizards

187eVSM Wizards



This tutorial will guide you through the steps to generate a

spaghetti layout using the Spaghetti Wizard.

Spaghetti Wizard Tutorial

10

189eVSM Wizards





1

Click to enable




3

4



2

Step 1: Start eVSM

191eVSM Wizards


Quick_eVSM








2

VSM




5

192


Learn eVSM Basics




3

Use the shape’s

right-mouse menus


4

eVSM Help resources are available in the

Learn module of the toolbar. Hover over

each one to see what they do.

1

193eVSM Wizards


Click the Open button. Select

Spaghetti in the Wizard column

and click OK.

Drag out the

red icon first.

This is very

important!

3

1

Initiate the map for the Spaghetti WizardStep 3:

The Spaghetti Wizard

stencil will open on

the left.

2

eVSM Data

WizSpaghet

ti

7.30.0187.0

Spaghetti Data

Open

194


Initiate the map for the Spaghetti Wizard

195eVSM Wizards


Draw/Import Floor MapStep 4:

Draw or import a floor map. Visio can

import most bitmap formats as well as

AutoCAD drawings. Either use the

“Insert” tab in Visio or simply copy and

paste the picture into a new drawing.

1

Scale

eVSM Data

WizSpaghet

ti

7.30.0187.0

196


Draw/Import Floor Map

Drag out a Spaghetti Scale shape and stretch

it out to exactly fit a known dimension on the

map. The known dimension could be a map

scale if available, or a floor dimension you

have measured. Enter the actual dimension

value on the scale shape by double-clicking it.

2

10

197eVSM Wizards


Add Spaghetti PlacesStep 5:

eVSM Data

WizSpaghet

ti

7.30.0187.0

Place

198


Add Spaghetti Places

Define Activity Centers by

dropping a Spaghetti Place icon

onto the diagram for each place,

then double-clicking each one to

name the Place.

1

10

199eVSM Wizards


Draw Spaghetti PathsStep 6:

eVSM Data

WizSpaghet

ti

7.30.0187.0

Any of the line tools in the

Drawing toolbar can be used

in Visio 2003/2007

Line tools in

Visio 2010

In Visio 2003/2007, the line drawing tools are

in the Drawing Toolbar. This can be opened

via the right-mouse menus on the Visio

Toolbars. In Visio 2010, the drawing tools are

near the center of the "Home" ribbon.

1

200


Draw Spaghetti Paths

Use the Visio line drawing tools to map the

paths. You must ensure that each path

starts and ends in a Spaghetti Place icon.

You can set color and line thickness of the

paths using standard Visio formatting.

2

10

201eVSM Wizards


Create Spaghetti ReportStep 7:

eVSM Data

WizSpaghet

ti

7.30.0187.0

202


Create Spaghetti Report

Click the Solve button. eVSM will create a

spreadsheet report of the paths. Note that

the Solve button recreates the Excel

report, it DOES NOT update it.

1

10

Solve

203eVSM Wizards



This tutorial will guide you through the steps to generate a

standard work chart using the Standard Work Wizard.

8

Day

Hr

60

Hr

Min

60

Min

Sec

eVSM Data

WizStandard

Work

7.20.0008.2

Demand

allA0010

DemandItemDay75

Takt Time Min6.40

Take Order

A00301

Manual Time

Min1

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Pick Lemons

for Prep

A00401

Manual Time

Min0.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Deliver to

Customer

A00501

Manual Time

Min1.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Prep Lemons

A00701

Manual Time

Min2

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Start Juicer

A00801

Manual Time

Min0.5

Machine Time

Min1.5

Manual Wait

Min1.5

Batch Size Item1

Unload Juicer

A00901

Manual Time

Min0.75

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

A0020

Server

1

Resource Takt

Min6.40

A0060

Maker

1

Resource Takt

Min6.40

Walk Time

Sec15

Walk Time

Sec1

Walk Time

Sec15

Walk Time

Sec10

Walk Time

Sec1

Walk Time

Sec1

SWCS Summary

Z0010all

CapacityItemDay

136.49

FTE Staff1.32

Standard Work Chart

Min0 1 2 3 4 5 6 7

Unload Juicer : A0090

Start Juicer : A0080

Prep Lemons : A0070

Maker : A0060

Deliver to Customer : A0050

Pick Lemons for Pre.. : A0040

Take Order : A0030

Server : A0020

Upstream Walk

Legend

Eff Manual Time

Eff Manual Wait

Eff Machine Time

Resource Time

Eff Act Takt Time

Operator Balance Chart

Min

0

1

2

3

4

5

6

7

A0020

Ser

ver

A0060

Mak

er

Resource Time

Legend

Resource Takt

Standard Work Wizard Tutorial

205eVSM Wizards




1

Click to enable




3

4



2

Step 1: Start eVSM

206

Copyright © 2015 The eVSM Group, All Rights Reserved 207eVSM Wizards


Quick_eVSM








2

VSM




5

208


Learn eVSM Basics




3

Use the shape’s

right-mouse menus


4

eVSM Help resources are available in

the Learn module of the toolbar. Hover

over each one to see what they do.

1

209eVSM Wizards


Click the Open button. Select

Standard Work in the Wizard

column and click OK.

Drag out the

red icons first.

This is very

important!

3

1

Enter the

amount of hours

per day.

4

Initiate the map Standard Work WizardStep 3:

The Standard Work

Wizard stencil will

open on the left.

2

8

Day

Hr

60

Hr

Min

60

Min

Sec

eVSM Data

WizStandard

Work

7.20.0008.2

StandardWork Data

Customer Center

Open

210


Initiate the map Standard Work Wizard

Demand

allA0010

DemandItemDay75

Takt Time MinAuto

Enter the

customer

demand

here.

5

211eVSM Wizards


Draw the FlowStep 4:

8

Day

Hr

60

Hr

Min

60

Min

Sec

eVSM Data

WizStandard

Work

7.20.0008.2

The green shapes are

called “Centers”. Use

the centers to represent

the flow.

1

Complete as shown

below, including

annotation and data

values.

2

Activity Center

Take Order

A00201

Manual Time

Min1

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Pick Lemons

for Prep

A00301

Manual Time

Min0.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Deliver to

Customer

A00401

Manual Time

Min1.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Prep Lemons

A00501

Manual Time

Min2

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Start Juicer

A00601

Manual Time

Min0.5

Machine Time

Min1.5

Manual Wait

Min1.5

Batch Size Item1

Unload Juicer

A00701

Manual Time

Min0.75

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Resource Center

A0100

Server

1

Resource Takt

MinAuto

A0110

Maker

1

Resource Takt

MinAuto

Do not change

any of the “Auto”

fields. These will

calculated later.

3

212


Draw the Flow

Demand

allA0010

DemandItemDay75

Takt Time MinAuto

213eVSM Wizards


Sequence ArrowsStep 5:

8

Day

Hr

60

Hr

Min

60

Min

Sec

eVSM Data

WizStandard

Work

7.20.0008.2

Hold down the SHIFT key and

select the centers in the order

shown here. This is the

sequence in which the server

will perform their tasks. Do

NOT connect a sequence

arrow from the last task back

to the server

1

Take Order

A00201

Manual Time

Min1

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Pick Lemons

for Prep

A00301

Manual Time

Min0.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Deliver to

Customer

A00401

Manual Time

Min1.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Prep Lemons

A00501

Manual Time

Min2

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Start Juicer

A00601

Manual Time

Min0.5

Machine Time

Min1.5

Manual Wait

Min1.5

Batch Size Item1

Unload Juicer

A00701

Manual Time

Min0.75

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

A0100

Server

1

Resource Takt

MinAuto

A0110

Maker

1

Resource Takt

MinAuto

A

B

C

D

Click the Sequence

button to add sequence

arrows.

2

Sequence

214


Sequence Arrows

Demand

allA0010

DemandItemDay75

Takt Time MinAuto

215eVSM Wizards


Sequence Arrows Part 2Step 6:

8

Day

Hr

60

Hr

Min

60

Min

Sec

eVSM Data

WizStandard

Work

7.20.0008.2

Sequence arrows have

been added with data on it

as well. Enter the Walk

Time from each center.

Double-click the unit to

change it from Min to Sec.

1

Take Order

A00201

Manual Time

Min1

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Pick Lemons

for Prep

A00301

Manual Time

Min0.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Deliver to

Customer

A00401

Manual Time

Min1.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Prep Lemons

A00501

Manual Time

Min2

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Start Juicer

A00601

Manual Time

Min0.5

Machine Time

Min1.5

Manual Wait

Min1.5

Batch Size Item1

Unload Juicer

A00701

Manual Time

Min0.75

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

A0100

Server

1

Resource Takt

MinAuto

A0110

Maker

1

Resource Takt

MinAuto

A

B

C

D

Walk Time

Sec15

Walk Time

Sec1

Walk Time

Sec15

Hold down the SHIFT

key and select the

centers in the order

shown here for the

second resource and

associated set of

activities.

2

216


Sequence Arrows Part 2

Demand

allA0010

DemandItemDay75

Takt Time MinAuto

Click the Sequence button to add

sequence arrows.

3

Sequence

217eVSM Wizards


Perform CalculationsStep 7:

8

Day

Hr

60

Hr

Min

60

Min

Sec

eVSM Data

WizStandard

Work

7.20.0008.2

Take Order

A0030

Manual Time

Min1

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Pick Lemons

for Prep

A0040

Manual Time

Min0.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Deliver to

Customer

A0050

Manual Time

Min1.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Prep Lemons

A0070

Manual Time

Min2

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Start Juicer

A0080

Manual Time

Min0.5

Machine Time

Min1.5

Manual Wait

Min1.5

Batch Size Item1

Unload Juicer

A0090

Manual Time

Min0.75

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

A0020

Server

Resource Takt

MinAuto

A0060

Maker

Resource Takt

MinAuto

Walk Time

Sec15

Walk Time

Sec1

Walk Time

Sec15

Walk Time

Sec10

Walk Time

Sec1

Walk Time

Sec1

Fill in the

remaining Walk

Times.

1

SWCS Summary

1

1

1

1

2

2

2

2

218


Perform Calculations

Demand

allA0010

DemandItemDay75

Takt Time MinAuto

Click the Solve button

in the toolbar.

4

SWCS Summary

Z0010all

CapacityItemDay

Auto

FTE StaffAuto

Drag out the

Summary Center

3

Click the Auto Path button

and the Auto Tag button to

create path numbers and

tags for each resource.

This is a critical step to get

the standard work chart to

plot in the correct order

2

Auto Path Auto Tag

Solve

219eVSM Wizards


Visualize with ChartsStep 8:

8

Day

Hr

60

Hr

Min

60

Min

Sec

Take Order

A0030

Manual Time

Min1

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Pick Lemons

for Prep

A0040

Manual Time

Min0.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Deliver to

Customer

A0050

Manual Time

Min1.5

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Prep Lemons

A0070

Manual Time

Min2

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

Start Juicer

A0080

Manual Time

Min0.5

Machine Time

Min1.5

Manual Wait

Min1.5

Batch Size Item1

Unload Juicer

A0090

Manual Time

Min0.75

Machine Time

Min0

Manual Wait

Min0

Batch Size Item1

A0020

Server

Resource Takt

Min6.40

A0060

Maker

Resource Takt

Min6.40

Walk Time

Sec15

Walk Time

Sec1

Walk Time

Sec15

Walk Time

Sec10

Walk Time

Sec1

Walk Time

Sec1

1

1

1

1

2

2

2

2

eVSM Data

WizStandard

Work

7.30.0000.1

220


Visualize with Charts

Demand

allA0010

DemandItemDay75

Takt Time Min6.40

All Auto fields are

now calculated.

1

SWCS Summary

Z0010all

CapacityItemDay

96.97

FTE Staff1.32

SWCS

Chart

Drag out the SWCS

chart shape and right-

click to Plot Chart.

3

Balance

Chart

Drag out the Balance

chart shape and right-

click to Plot Chart.

2

Standard Work Chart

Min0 1 2 3 4 5 6 7

Unload Juicer : A0090

Start Juicer : A0080

Prep Lemons : A0070

Maker : A0060

Deliver to Customer : A0050

Pick Lemons for Pre.. : A0040

Take Order : A0030

Server : A0020

Upstream Walk

Legend

Eff Manual Time

Eff Manual Wait

Eff Machine Time

Resource Time

Eff Act Takt Time

Operator Balance Chart

Min

0

1

2

3

4

5

6

7

A0020

Ser

ver

A0060

Mak

er

Resource Time

Legend

Resource Takt

221eVSM Wizards



eVSM Training Evaluation Form

Name:_____________________________ Title/Role:___________________

Email:_____________________________

Please indicate your impressions of the items listed below.

Strongly

Agree

Agree Neutral Disagree Strongly

Disagree

1. The training met my expectations

2. I will be able to apply the

knowledge learned.

3. The training objectives for each

topic were identified and followed.

4. The content was organized and easy

to follow.

5. The materials distributed were

pertinent and useful.

6. The trainer was knowledgeable.

7. The quality of instruction was good.

8. The trainer met the training

objectives.

9. Class participation and interaction

were encouraged.

10. Adequate time was provided for

questions and discussion.

11. How do you rate the training overall?

q q q q q

q q q q q

q q q q q

q q q q q

q q q q q

q q q q q

q q q q q

q q q q q

q q q q q

q q q q q

q q q q q

Excellent Good Average Poor Very Poor

12. What aspects of the training could be improved?

223eVSM Wizards


eVSM Training Evaluation Form

THANK YOU FOR YOUR FEEDBACK!

1. Describe the next VSM activity you are involved in. (Role, Training, Purpose, Team, Sponsor)

2. Do you plan to use the tools you have learned about in the workshop? If so, how?

3. What challenges do you envisage in applying these tools?

4. What advantages will you realize in applying these tools?

5. Other Comments?

224

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Improving Mixed Model Value Streams - eVSM · 2017-07-18 · Hand Exercises 161 ACME Mixed Model...

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