LEAN ASSIGNMENT – 4

You are the CI manager and you have been asked by the CEO to improve the lead time for the Tail Gate production line.

(1) Develop a Current State Value Stream Map base on the information below:

a. Customer name: Ford Motor

b. Supplier name: Eaton Yale Ltd (Tail Gate manufacturer)
c. TW steel (raw steel plates) provides raw steel to Eaton Yale
d. Eaton Yale Products: Tail gate for F -150 and F- 250 pickup trucks
i. Part number for F-150  TG – 150
ii. Part number for F-250  TG – 250
e. Ford Motor scheduling department provides monthly forecast to Eaton Yale
f. Ford Motor scheduling department provides daily requirement to Eaton Yale every Monday at
11:00AM for the next 10 days
g. All companies work 20 days per month (weekday only)
h. Eaton Yale Calculate the raw steel requirement and fax to TW steel weekly
i. TW Steel ship raw steel plate via rail twice a week (Monday and Wednesday)
j. The agreement between TW Steel and Eaton Yale is to have 5 days Raw steel inventory
k. Ford Motor assemble
i. F -150  1200 per month
ii. F-250  600 per month
l. Ford Motor operate 3 shifts per day
m. Each shift has two 15 minutes break and 30 minutes lunch

More information:
Inventory between process
Process Cycle time (minutes) Change Over time (CO) Rework Rate Up time
TG 150 TG 250
Stamping 0.7 3 hours 0% 90%
Forming 246 120 10 10 hours 0% 85%
Heat Stress 126 97 13 4 hours 0% 40%
Grinding 98 60 13 0.3 hour 0% 90%
Assembly casing 221 122 17 2 hours 25% 100%
Assembly detail 27 14 12 0.2 hours 30% 100%
Shipping 190 76
Solution:

Production Control

DAILY PLAN

STAMPING FORMING HEAT STRESS GRINDING ASSEMBLY ASSEMBLY

CASING DETAIL

C/T:0.7 mn C/T:10mn C/T:13 mn C/T:13mn

C/T:17 mn C/T:12 mn
C/O:3hrs C/O:10hrs C/O:4hrs C/O:0.3hrs SHIPPING
C/O:2hrs C/O:0.2hrs
RR:0% RR:0% RR:0% RR:0%
246, 126, RR:25% RR:30% 190,
98, 221, 27,
Uptime:90% 120 Uptime:85% 97 Uptime:40% Uptime:90 76
60 27 Uptime:10 14
% Uptime:100%
0%

5 Days 4.06 Days 2.47 Days 1.75Days 3.7 Days 0.45 Days 2.95 Days

0.7min 10min 13min 13min 17min 12min

Total Lead Time: 20.38 Days

Total Processing Time: 65.7 mins

(2) Answer the eight questions of Future State Value Stream Map and develop a Future State Value
Stream Map

(1) What is the Takt time?

(2) Build/process directly to shipping or to a Finished Goods supermarket?

(3) Where can continuous flow be used?

(4) Where are supermarket or FIFO pull systems needed?

(5) At what single point (the pacemaker) in the Value Stream is processing/production triggered?

(6) How is production mix leveled at the pacemaker?

(7) How is production volume leveled at the pacemaker? (i.e. Pitch: what increment of work will be
released and taken away at the pacemaker process?)
 (8) What process improvements are necessary for the Future State to become a reality? (e.g. uptime,
changeover, training)

Solution:

1) Takt Time = Time Available / Demand

TT = (21hrs/day) / (90 ) = 14 minutes

2) Build/process directly to shipping or to a Finished Goods supermarket:

 Monthly

Production Control
Monthly

DAILY PLAN Daily Shipping Plan

STAMPING FORMING HEAT STRESS GRINDING ASSEMBLY

ASSEMBLY
CASING DETAIL

C/T:0.7 mn C/T:10mn C/T:13 mn C/T:13mn

C/T:17 mn C/T:12 mn
C/O:3hrs C/O:10hrs C/O:4hrs C/O:0.3hrs SHIPPING
C/O:2hrs C/O:0.2hrs
RR:0% RR:0% RR:0% RR:0%
246, 126, RR:25% RR:30% 190,
98, 221, 27,
Uptime:90% 120 Uptime:85% 97 Uptime:40% Uptime:90 76
60 27 Uptime:10 14
% Uptime:100%
0%

5 Days 4.06 Days 2.47 Days 1.75Days 3.7 Days 0.45 Days 2.95 Days

0.7min 10min 13min 13min 17min 12min

3)

Takt Time= 14 mins

17 12
13 13

10

0.7

Forming Heat Grinding Assembly Assembly

Stamp Detail
Stress Casing
 Production Control
Monthly

DAILY PLAN Daily Shipping Plan

STAMPING FORMING HEAT STRESS GRINDING ASSEMBLY

ASSEMBLY
CASING DETAIL

C/T:0.7 mn C/T:10mn C/T:13 mn C/T:13mn

C/T:17 mn C/T:12 mn
C/O:3hrs C/O:10hrs C/O:4hrs C/O:0.3hrs SHIPPING
C/O:2hrs C/O:0.2hrs
RR:0% RR:0% RR:0% RR:0%
246, 126, RR:25% RR:30% 190,
98, 221, 27,
Uptime:90% 120 Uptime:85% 97 Uptime:40% Uptime:90 76
60 27 Uptime:10 14
% Uptime:100%
0%

5 Days 4.06 Days 2.47 Days 1.75Days 3.7 Days 0.45 Days 2.95 Days

0.7min 10min 13min 13min 17min 12min

 Production Control
Monthly

DAILY PLAN Daily Shipping Plan

STAMPING FORMING HEAT STRESS GRINDING ASSEMBLY

ASSEMBLY
CASING DETAIL

C/T:0.7 mn C/T:10mn C/T:13 mn C/T:13mn

C/T:17 mn C/T:12 mn
C/O:3hrs C/O:10hrs C/O:4hrs C/O:0.3hrs SHIPPING
C/O:2hrs C/O:0.2hrs
RR:0% RR:0% RR:0% RR:0%
246, 126, RR:25% RR:30% 190,
98, 221, 27,
Uptime:90% 120 Uptime:85% 97 Uptime:40% Uptime:90 76
60 27 Uptime:10 14
% Uptime:100%
0%

5 Days 4.06 Days 2.47 Days 1.75Days 3.7 Days 0.45 Days 2.95 Days

0.7min 10min 13min 13min 17min 12min

Takt Time= 14 mins

17 12
13 13

10

0.7

Forming Heat Grinding Assembly Assembly

Stamp Detail
Stress Casing
 4)

Ideal No of Operators = Total Work Content / Takt Time

= 65 / 14 = 4.64 (or) = 5 operators

5)

Takt Time= 14 mins 13x5=65 mins

CT = 13
min

3 3 3

12

13
10
10

10

0.7 1

Forming Heat Grinding Assembly Assembly

Stamp Detail
Stress Casing
 Production Control
Monthly

DAILY PLAN Daily Shipping Plan

STAMPING FORMING HEAT STRESS GRINDING ASSEMBLY

ASSEMBLY
CASING DETAIL

C/T:0.7 mn C/T:10mn C/T:13 mn C/T:13mn

C/T:17 mn C/T:12 mn
C/O:3hrs C/O:10hrs C/O:4hrs C/O:0.3hrs SHIPPING
C/O:2hrs C/O:0.2hrs
RR:0% RR:0% RR:0% RR:0%
246, 126, RR:25% RR:30% 190,
98, 221, 27,
Uptime:90% 120 Uptime:85% 97 Uptime:40% Uptime:90 76
60 27 Uptime:10 14
% Uptime:100%
0%

5 Days 4.06 Days 2.47 Days 1.75Days 3.7 Days 0.45 Days 2.95 Days

0.7min 10min 13min 13min 17min 12min

Production Control
10 day forecast

Daily Shipping
Plan

Forming, Heat Stress, Grinding and

STAMPING Assembly Casing and Assembly Detail

C/T= 0.7 min C/T = 13 Mins

C/O= 3 hrs Shipping
Takt Time= 14 Mins
2.95 Days
5 Days Uptime=90%
5X
1X
6)

Production Control
10 day forecast

Daily Shipping
Plan
1

Forming, Heat Stress, Grinding and

STAMPING Assembly Casing and Assembly Detail

C/T= 0.7 min C/T = 13 Mins

C/O= 3 hrs Shipping
Takt Time= 14 Mins
4.06 Days 2.95 Days
5 Days Uptime=90%
5X
1X

Production Control
10 day forecast

Daily Shipping
Plan
1

1
Forming, Heat Stress, Grinding and
STAMPING Assembly Casing and Assembly Detail

C/T= 0.7 min C/T = 13 Mins

C/O= 3 hrs Shipping
Takt Time= 14 Mins
4.06 Days 2.95 Days
5 Days Uptime=90%
5X
1X
7)
Production Control
10 day forecast

Daily Shipping
Plan
1
BATCH

Forming, Heat Stress, Grinding and

STAMPING Assembly Casing and Assembly Detail

C/T= 0.7 min C/T = 13 Mins

Delivery trays
C/O= 3 hrs Shipping
Takt Time= 14 Mins
4.06 Days 2.95 Days
5 Days Uptime=90%
5X
1X

Production Control
10 day forecast

Daily Shipping
Plan
BATCH 1
XOXO
XOXO 1
1
Forming, Heat Stress, Grinding and 1
STAMPING Assembly Casing and Assembly Detail

C/T= 0.7 min C/T = 13 Mins

Delivery trays
C/O= 3 hrs Shipping
Takt Time= 14 Mins
4.06 Days 2.95 Days
2 Days Uptime=90%
5X
1X
8)

Production Control
10 day forecast

Daily Shipping
Plan
BATCH 1
XOXO
XOXO 1
1
Forming, Heat Stress, Grinding and 1
STAMPING Assembly Casing and Assembly Detail

C/T= 0.7 min C/T = 13 Mins

Delivery trays
C/O= 3 hrs Shipping
Takt Time= 14 Mins
4.06 Days 2.95 Days
2 Days Uptime=90%
5X
1X

5 days
2 Days 4.06 Days 2.95 Days 65.7 mins
0.7 mins 65 mins