Value Stream MappingValue Stream Mapping
VALUE STREAMVALUE STREAM
All the actions required to bringAll the actions required to bring
a product through its main flows,a product through its main flows,
door-to-door, from raw materialdoor-to-door, from raw material
to the arms of the customer.to the arms of the customer.
VALUE STREAM MAPPINGVALUE STREAM MAPPING
A pencil and paper tool that lets A pencil and paper tool that lets
you SEE and UNDERSTAND the you SEE and UNDERSTAND the
flow of material and information flow of material and information
as a product makes its way as a product makes its way
through the value stream.through the value stream.
• Visualize the entire value stream.Visualize the entire value stream.• Link material + information flows.Link material + information flows.
V.S. MAPPING BENEFITSV.S. MAPPING BENEFITS
PRODUCTION FLOW PRODUCTION FLOW
materialmaterial
informationinformation
• See the sources of waste.See the sources of waste.• Highlight the real decision points.Highlight the real decision points.• Link actions to flow results.Link actions to flow results.• Blueprint your implementation.Blueprint your implementation.• Speak a common language.Speak a common language.
V.S. MAPPING BENEFITSV.S. MAPPING BENEFITS
• Visualize the entire value stream.Visualize the entire value stream.• Link material + information flows.Link material + information flows.
MAPPING THE ‘BIG’ PICTUREMAPPING THE ‘BIG’ PICTURE
seniorseniormgmt.mgmt.
fronfronttlineslines
ELIMINATIONELIMINATIONOF WASTEOF WASTE
VALUE STREAMVALUE STREAMIMPROVEMENTIMPROVEMENT
focusfocus
Value stream improvements driveValue stream improvements drivewaste elimination projects.waste elimination projects.
VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS
product familyproduct family
current-current-statestate
drawingdrawing future-state future-state
drawingdrawing
work plan work plan
VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS
product familyproduct family
current-current-statestate
drawingdrawing future-state future-state
drawingdrawing
work plan work plan
product familyproduct family
PRODUCT FAMILYPRODUCT FAMILY
A group of products thatA group of products that
passes through commonpasses through common
processing steps and overprocessing steps and over
common equipment in yourcommon equipment in your
downstreamdownstream processes processes..
PRODUCT FAMILY ASPECTSPRODUCT FAMILY ASPECTS
Manufacturing processManufacturing process
How many part numbers How many part numbers
“ “Spin-off” TestSpin-off” Test
PROCESSPROCESS
SPIN-OFF TESTSPIN-OFF TEST Landlocked for future growthLandlocked for future growth Must relocate part of businessMust relocate part of business It must be totally self-sufficientIt must be totally self-sufficient
EquipmentEquipment PersonelPersonel Support activitiesSupport activities
Cannot come back for servicesCannot come back for services Repeat until all product families Repeat until all product families are defined.are defined.
PRODUCT MIX MATRIXPRODUCT MIX MATRIX
AABBCCDDEEFFGG
XXXXXX
XXXX
XXXXXXXXXX
XXXXXXXXXXXXXX
XX
XXXX
XXXXXX
XXXX
XXXXXX
XXXX
XXXXXXXXXX
XXXX
PR
OD
UC
TS
PR
OD
UC
TS
1 2 3 4 5 6 7 81 2 3 4 5 6 7 8
Assembly Steps & EquipmentAssembly Steps & Equipment
MACHINE LOADING ANALYSIS
Part 1 - Pieces per HourPART # DESCRIPTION VOLUME STOCK MACH 1 MACH 2 MACH 3 MACH 4 MACH 5 MACH 6 MACH 7 MACH 8 MACH 9 MACH 10
0000-001 PRODUCT 1 48000 XXXX-01 2610000-002 PRODUCT 2 2500 XXXX-02 125 61 81 1590000-003 PRODUCT 3 2000 XXXX-03 98 139 293 2750000-004 PRODUCT 4 7500 XXXX-04 72 64 107 1840000-005 PRODUCT 5 64000 XXXX-05 95 880000-006 PRODUCT 6 61000 XXXX-06 76 480000-007 PRODUCT 7 7500 XXXX-07 2240000-008 PRODUCT 8 24000 XXXX-08 1930000-009 PRODUCT 9 48000 XXXX-09 73 750000-010 PRODUCT 10 61000 XXXX-10 96 610000-011 PRODUCT 11 48000 XXXX-11 2220000-012 PRODUCT 12 24000 XXXX-12 1360000-013 PRODUCT 13 64000 XXXX-13 2360000-014 PRODUCT 14 55000 XXXX-14 2350000-015 PRODUCT 15 48000 XXXX-15 2220000-016 PRODUCT 16 48000 XXXX-16 1360000-017 PRODUCT 17 48000 XXXX-17 237 2000000-018 PRODUCT 18 55000 XXXX-18 90 930000-019 PRODUCT 19 55000 XXXX-19 292 1860000-020 PRODUCT 20 64000 XXXX-20 254 333
834500
Part 2 - Annual Hours per MachinePART # DESCRIPTION VOLUME STOCK MACH 1 MACH 2 MACH 3 MACH 4 MACH 5 MACH 6 MACH 7 MACH 8 MACH 9 MACH 10
0000-001 PRODUCT 1 48000 XXXX-01 184 0 0 0 0 0 0 0 0 00000-002 PRODUCT 2 2500 XXXX-02 20 41 31 16 0 0 0 0 0 00000-003 PRODUCT 3 2000 XXXX-03 20 14 7 7 0 0 0 0 0 00000-004 PRODUCT 4 7500 XXXX-04 104 117 70 41 0 0 0 0 0 00000-005 PRODUCT 5 64000 XXXX-05 674 727 0 0 0 0 0 0 0 00000-006 PRODUCT 6 61000 XXXX-06 803 1271 0 0 0 0 0 0 0 00000-007 PRODUCT 7 7500 XXXX-07 33 0 0 0 0 0 0 0 0 00000-008 PRODUCT 8 24000 XXXX-08 124 0 0 0 0 0 0 0 0 00000-009 PRODUCT 9 48000 XXXX-09 0 0 0 0 658 640 0 0 0 00000-010 PRODUCT 10 61000 XXXX-10 0 0 0 0 635 1000 0 0 0 00000-011 PRODUCT 11 48000 XXXX-11 0 0 0 0 216 0 0 0 0 00000-012 PRODUCT 12 24000 XXXX-12 0 0 0 0 176 0 0 0 0 00000-013 PRODUCT 13 64000 XXXX-13 0 0 0 0 271 0 0 0 0 00000-014 PRODUCT 14 55000 XXXX-14 0 0 0 0 234 0 0 0 0 00000-015 PRODUCT 15 48000 XXXX-15 0 0 0 0 216 0 0 0 0 00000-016 PRODUCT 16 48000 XXXX-16 0 0 0 0 353 0 0 0 0 00000-017 PRODUCT 17 48000 XXXX-17 0 0 0 0 203 0 240 0 0 00000-018 PRODUCT 18 55000 XXXX-18 0 0 0 0 611 0 591 0 0 00000-019 PRODUCT 19 55000 XXXX-19 0 0 0 0 188 0 296 0 0 00000-020 PRODUCT 20 64000 XXXX-20 0 0 0 0 252 0 0 192 0 0
834500 1963 2171 108 64 4014 1640 1127 192 0 0
PRODUCT FAMILY ASPECTSPRODUCT FAMILY ASPECTS
“ “Spin-off” TestSpin-off” Test
Manufacturing processManufacturing process
How many part numbersHow many part numbers
Customer names Customer names
Customer volumesCustomer volumes
Delivery frequencyDelivery frequency
PROCESSPROCESS
CUSTOMERCUSTOMER
CUSTOMER REQUIREMENTSCUSTOMER REQUIREMENTS
Customer Volume Part #s Ship Freq. PackageCustomer Volume Part #s Ship Freq. Package
AcmeAcme
PinnaclePinnacle
VertexVertex
CrownCrown
3000/wk3000/wk
1500/wk1500/wk
1000/wk1000/wk
500/wk500/wk
44
22
22
22
DailyDaily
DailyDaily
WeeklyWeekly
MonthlyMonthly
10/box10/box
10/box10/box
10/box10/box
10/box10/box
Product Family:Product Family: Tilt Mechanisms Tilt Mechanisms
VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS
product familyproduct family
current-current-statestate
drawingdrawing future-state future-state
drawingdrawing
work plan work plan
current-current-statestate
drawingdrawing
START-UP MAPPING TIPSSTART-UP MAPPING TIPS
1.1. One person does the entire map. One person does the entire map.22. Start at the customer end.. Start at the customer end.3.3. Walk the actual pathways of both Walk the actual pathways of both
material and information flow.material and information flow.4.4. Do a quick walk-through first. Do a quick walk-through first.5.5. Do a detailed walk-through, using Do a detailed walk-through, using
a stop watch to collect actuala stop watch to collect actualtimes and counting inventory.times and counting inventory.
6.6. Draw by hand in pencil. Draw by hand in pencil.
WHY IN PENCIL, BY HAND?WHY IN PENCIL, BY HAND?
No delays
You do it, youunderstand it Focus on flow,
not a computer
Fixing your ownmistakes fine-tunes skills
MAP LAYOUT GEOGRAPHYMAP LAYOUT GEOGRAPHY
1111
1717
CustomerInfo.
Process Flow Information
SupplierInfo.
Production ControlInfo.
Time Line
START WITH THE CUSTOMERSTART WITH THE CUSTOMERCustomer Requirements:Customer Requirements:• State Street Assembly Co.State Street Assembly Co.• 18,400 pieces per month18,400 pieces per month
- 12,000 Type LH- 12,000 Type LH- 6,400 Type RH- 6,400 Type RH
• 20 units per tray 20 units per tray • Operates on two shiftsOperates on two shifts• 1 truck per day1 truck per day
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
Icons:Icons:
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
COLLECTING PROCESS DATACOLLECTING PROCESS DATA Number of product variations (P/N’s)Number of product variations (P/N’s) Machine(s) usedMachine(s) used C/T (cycle time)C/T (cycle time) C/O (changeover time)C/O (changeover time) Uptime (on-demand machine time)Uptime (on-demand machine time) EPE (production sequence time)EPE (production sequence time) Number of operatorsNumber of operators Pack sizePack size Working time (minus breaks)Working time (minus breaks) Scrap rateScrap rate
200 T200 TPresPresss
Weld IIWeld II Weld IWeld I
Assembly IAssembly I Assembly IIAssembly II
WeldingWeldingInspectionInspection
AreaArea
PRESS DEPT.PRESS DEPT.
WELDING DEPT.WELDING DEPT.
SHIPPINGSHIPPING
ASSEMBLY DEPT.ASSEMBLY DEPT.
Steel CoilSteel CoilStorageStorage
Stamped PartsStamped PartsStorageStorage
FinishedFinishedGoodsGoodsStorageStorage
ACME STAMPING FACTORY LAYOUTACME STAMPING FACTORY LAYOUT
= WIP in Baskets= WIP in Baskets = Finished Goods in Trays= Finished Goods in Trays
Welded Parts Welded Parts StorageStorage
FINALFINALIINNSSPPEECCTTIIOONN
ACME STAMPING MATERIAL FLOWACME STAMPING MATERIAL FLOW
1. Stamping1. Stamping
2. Spot-welding Workstation #12. Spot-welding Workstation #1
3. Spot-welding Workstation #23. Spot-welding Workstation #2
4. Assembly Workstation #14. Assembly Workstation #1
5. Assembly Workstation #25. Assembly Workstation #2
6. Shipping6. Shipping
Where should we start?Where should we start?
1xDaily
1xDaily
SHIPPING
Staging
I2700 L2700 L1440 R1440 R
I
ACME STAMPING PROCESSACME STAMPING PROCESS
ShippingShipping::• 1 truck per day1 truck per day• 20 pieces/tray20 pieces/tray• 10 trays/pallet10 trays/pallet• 30 “L” pallets/day30 “L” pallets/day• 16 “R” pallets/day16 “R” pallets/day• Inventory:Inventory: - 2700 L- 2700 L - 1440 R- 1440 R
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
SHIPPINGI
2700 L1440 R
Staging
1xDaily
Assembly #2Assembly #2• 2 part numbers2 part numbers• 1 operator1 operator• 2 shifts2 shifts• No setupsNo setups• 40 sec. cycle time40 sec. cycle time• 100% uptime100% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 1200 LH- 1200 LH - 640 RH- 640 RH
ACME STAMPING PROCESSACME STAMPING PROCESSIcons:Icons:
ASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
I1200 L1200 L 640 R640 R
I
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
I1200 L 640 R
I2700 L1440 R
Staging
Assembly #1Assembly #1• 2 part numbers2 part numbers• 1 operator1 operator• 2 shifts2 shifts• No setupsNo setups• 62 sec. cycle time62 sec. cycle time• 100% uptime100% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 1600 LH- 1600 LH - 850 RH- 850 RH
ACME STAMPING PROCESSACME STAMPING PROCESSIcons:Icons:
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
I1600 L1600 L 850 R850 R
I
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
I1600 L 850 R
I1200 L 640 R
I2700 L1440 R
Staging
Spot Weld #2Spot Weld #2::• 2 part numbers2 part numbers• 1 operator1 operator• 2 shifts2 shifts• 10 min. setup10 min. setup• 46 sec. cycle time46 sec. cycle time• 80% uptime80% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 1100 LH- 1100 LH - 600 RH- 600 RH
ACME STAMPING PROCESSACME STAMPING PROCESSIcons:Icons:
S.WELD #2
1
C/T = 46 seconds
C/O = 10 min.Uptime = 80%
2 Shifts27,600 sec/shift
I1100 L1100 L 600 R600 R
I
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
S. WELD #2
1
C/T = 46 secondsC/O = 10 minutes
Uptime = 80%2 Shifts
27,600 sec/shift
I1100 L 600 R
I1600 L 850 R
I1200 L 640 R
I2700 L1440 R
Staging
Spot Weld #1Spot Weld #1::• 2 part numbers2 part numbers• 1 operator1 operator• 2 shifts2 shifts• 10 min. setup10 min. setup• 39 sec. cycle time39 sec. cycle time• 100% uptime100% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 4600 LH- 4600 LH - 2400 RH- 2400 RH
ACME STAMPING PROCESSACME STAMPING PROCESSIcons:Icons:
S.WELD #1
1
C/T = 39 seconds
C/O = 10 min.Uptime = 100%
2 Shifts27,600 sec/shift
I4600 L4600 L2400 R2400 R
I
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
S. WELD #2
1
C/T = 46 secondsC/O = 10 minutes
Uptime = 80%2 Shifts
27,600 sec/shift
S. WELD #1
4600 L2400 R 1
C/T = 39 secondsC/O = 10 minutes
Uptime = 100%2 Shifts
27,600 sec/shift
I I1100 L 600 R
I1600 L 850 R
I1200 L 640 R
I2700 L1440 R
Staging
StampingStamping::• 200 Ton Press200 Ton Press• Auto. Coil FeedAuto. Coil Feed• Run every 2 wks.Run every 2 wks.• 1 hour setup1 hour setup• 1 sec. cycle time1 sec. cycle time• 85% uptime85% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 5 days of Coils- 5 days of Coils
ACME STAMPING PROCESSACME STAMPING PROCESSIcons:Icons:
STAMPING
C/T = 1 secondC/O = 1 hour
Uptime = 85%EPE = 2 weeks27,600 sec/shift
ICoilsCoils
5 days5 days200 T
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
S. WELD #2
1
C/T = 46 secondsC/O = 10 minutes
Uptime = 80%2 Shifts
27,600 sec/shift
S. WELD #1
1
C/T = 39 secondsC/O = 10 minutes
Uptime = 100%2 Shifts
27,600 sec/shift
I1100 L 600 R
I1600 L 850 R
I1200 L 640 R
I2700 L1440 R
Staging4600 L2400 R
STAMPINGI
Coils5 days
C/T = 1 secondsC/O = 1 hour
Uptime = 85%27,600 sec./shiftEPE = 2 weeks
I200 T
STAMPING
ADD THE SUPPLIER(S)ADD THE SUPPLIER(S)
Michigan Steel CoMichigan Steel Co::
• 1 truck Tuesday1 truck Tuesday
• 1 truck Thursday1 truck Thursday
• 500 foot coils500 foot coils Tues. +Thurs
MichiganSteel Co.
500 ft. coils
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
S. WELD #2
1
C/T = 46 secondsC/O = 10 minutes
Uptime = 80%2 Shifts
27,600 sec/shift
S. WELD #1
4600 L2400 R 1
C/T = 39 secondsC/O = 10 minutes
Uptime = 100%2 Shifts
27,600 sec/shift
STAMPINGI
Coils5 days
C/T = 1 secondsC/O = 1 hour
Uptime = 85%27,600 sec./shift
EPE = 2 weks
I I1100 L 600 R
I1600 L 850 R
I1200 L 640 R
I2700 L1440 R
Staging200 T
MichiganSteel Co.
500 ft. coils
Tues. +Thurs.
This is theMaterial Flow
INDoor
Door to Door Value Stream
OUTDoor
Acme Production ControlAcme Production Control::• 30/60/90 day forecasts30/60/90 day forecasts from customerfrom customer• 6 week forecast to supplier6 week forecast to supplier• Weekly supplier releasesWeekly supplier releases• Daily firm order from theDaily firm order from the customercustomer• Weekly MRP generationWeekly MRP generation• Weekly build schedules toWeekly build schedules to internal operationsinternal operations• Daily shipping scheduleDaily shipping schedule
ADD INFORMATION FLOWADD INFORMATION FLOWIcons:Icons:
PRODUCTIONCONTROL
MRP
DailyOrder
WeeklySchedule
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
S. WELD #2
1
C/T = 46 secondsC/O = 10 minutes
Uptime = 80%2 Shifts
27,600 sec/shift
S. WELD #1
4600 L2400 R 1
C/T = 39 secondsC/O = 10 minutes
Uptime = 100%2 Shifts
27,600 sec/shift
STAMPINGI
Coils5 days
C/T = 1 secondsC/O = 1 hour
Uptime = 85%27,600 sec./shiftEPE = 2 weeks
I I1100 L 600 R
I1600 L 850 R
I1200 L 640 R
I2700 L1440 R
Staging200 T
MichiganSteel Co.
500 ft. coils
Tues. +Thurs.
PRODUCTIONCONTROL
MRPDailyOrder
30/60/90 dayForecasts
WeeklyRelease
6-weekForecasts
Weekly Schedule
Daily ShipSchedule
ADD THE TIME LINEADD THE TIME LINE
• Process leadtime is usually the CycleProcess leadtime is usually the Cycle Times (Value Added Time) for all ofTimes (Value Added Time) for all of the operations in the process.the operations in the process.
• Inventory leadtime is the time it takesInventory leadtime is the time it takes to work through the queues of stockto work through the queues of stock throughout the Value Stream.throughout the Value Stream.
Inventory Days =Inventory Days = Amount on HandAmount on Hand
Daily Customer NeedDaily Customer Need
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
S. WELD #2
1
C/T = 46 secondsC/O = 10 minutes
Uptime = 80%2 Shifts
27,600 sec/shift
S. WELD #1
4600 L2400 R 1
C/T = 39 secondsC/O = 10 minutes
Uptime = 100%2 Shifts
27,600 sec/shift
STAMPINGI
Coils5 days
C/T = 1 secondC/O = 1 hour
Uptime = 85%27,600 sec./shiftEPE = 2 weeks
I I1100 L 600 R
I1600 L 850 R
I1200 L 640 R
I2700 L1440 R
Staging200 T
MichiganSteel Co.
500 ft. coils
Tues. +Thurs.
PRODUCTIONCONTROL
MRPDailyOrder
30/60/90 dayForecasts
WeeklyRelease
6-weekForecasts
Weekly Schedule
Daily ShipSchedule
1 second 39 sec. 62 sec. 40 sec. ValueAddedTime
= 188 sec.46 sec.
5 days 7.6 days 1.8 days
2.7 days
2 days 4.5 days
ProductionLeadtime
23.6days=
IDENTIFY OPPORTUNITIESIDENTIFY OPPORTUNITIES
• The Current State Map shows what is The Current State Map shows what is happening “right now.”happening “right now.”
• It identifies wasteful steps and slow-down It identifies wasteful steps and slow-down causes.causes.
• It helps visualize how operations can be It helps visualize how operations can be combined to “flow” production.combined to “flow” production.
• It lets you see where “pull” systems make It lets you see where “pull” systems make sense when the product can’t flow.sense when the product can’t flow.
• It shows how the improvements impact the It shows how the improvements impact the value streamvalue stream..
CURRENT STATE MAPCURRENT STATE MAP
State StreetAssembly
18,400 pcs/mo
- 12,000 LH- 6,400 RH
Tray = 20 pcs2 shifts
1xDaily
SHIPPINGASSEMBLY #2
1
C/T = 40 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
ASSEMBLY #1
1
C/T = 62 secondsC/O = 0
Uptime = 100%2 Shifts
27,600 sec/shift
S. WELD #2
1
C/T = 46 secondsC/O = 10 minutes
Uptime = 80%2 Shifts
27,600 sec/shift
S. WELD #1
4600 L2400 R 1
C/T = 39 secondsC/O = 10 minutes
Uptime = 100%2 Shifts
27,600 sec/shift
STAMPINGI
Coils5 days
C/T = 1 secondC/O = 1 hour
Uptime = 85%27,600 sec./shiftEPE = 2 weeks
I I1100 L 600 R
I1600 L 850 R
I1200 L 640 R
I2700 L1440 R
Staging200 T
MichiganSteel Co.
500 ft. coils
Tues. +Thurs.
PRODUCTIONCONTROL
MRPDailyOrder
30/60/90 dayForecasts
WeeklyRelease
6-weekForecasts
Weekly Schedule
Daily ShipSchedule
1 second 39 sec. 62 sec. 40 sec. ValueAddedTime
= 188 sec.46 sec.
5 days 7.6 days 1.8 days
2.7 days
2 days 4.5 days
ProductionLeadtime
23.6days=
“flow” cell pullpullpull
TWI CASE STUDYTWI CASE STUDY
• Read through the TWI Case Study Read through the TWI Case Study hand out information.hand out information.
• Draw a Current State Map, using the Draw a Current State Map, using the tools and techniques described in tools and techniques described in this section.this section.
• Return to class prepared to discuss Return to class prepared to discuss your map and why you drew it that your map and why you drew it that way.way.
C/T = oper 10 sec mach 30 secC/O = 15 min - 1
hrUptime 90%
TWI CURRENT STATE MAP
OE + AftermarketCustomers
24,000 pcs/mo240 P/N’s
25-200 pc ordersBox = 5 pcs
VariousDaily
SHIPPINGASSEMBLY
6
C/T = 195 sec total
C/O = 10 minUptime = 100%
3 end fittings6 combos/rod
DEFLASH
1
WELD #2
1
WELD #1
5 days
1
MACHINING
IForgings20 days
I I3 days
I3 days
I6 days
I4 days Staging
2xMonthly
Orders60 days out
Orders
Daily Priorities
Daily ShipSchedule
30 sec. 30 sec.
2 days
30 sec.
20 days 5 days 3 days 3 days 5 days 6 days
Outside Painter
I5 days
Daily
Daily
MichiganSteel Co.
CUTI
Rods20 days
C/T = 15 secondsC/O = 15-60 min.Uptime = 100%
1
4 days
C/T = oper 10 sec mach 30 secC/O = 15 min - 1
hrUptime 80%
C/T = oper 10 sec mach 30 secC/O = 15 min - 1
hrUptime 100%
LT =48 days
I 2 days
IndiannaCastings
Forgings12 week LT
Rods16 week LT
Orders
ShopOrders To Weld Area
Supervisor
PRODUCTIONCONTROL
195 sec.
4 days
I
Size Change2 weeks out
C/T = 30 seconds2
pieces/assemblyC/O = 2 hoursUptime = 85%
60 sec. VA =345 sec