Documente Academic
Documente Profesional
Documente Cultură
Jason Fretz
Brian Grannan
Aaron Lininger
Jeff Lovell
Layout
Finished Goods
.Time? days
Inv ? days ? days ? days TPc
/t = ?
.Time
Proc ? days ? days ? days
Data Collection
8
Demand Chain Solutions
2
Introduction to Value Stream Mapping
Definition of Value Stream
Raw Finished
Material Product
Customer
Xpcs/ month
Std Pack Qty
Steel Supplier PC & L # Shifts
Level Box
DA1
Daily DA2
DA3
6 x / Day
Layout
AND...
Eliminate Waste
8
Demand Chain Solutions
1
Introduction to Value Stream Mapping
The Process
Customer
MRP MSS
X pcs/month
# times/day
Layout
and Inv.Time
Proc.Time
? days
? days
? days
? days
? days
? days
? days
TPc/t = ?
Training
8
Demand Chain Solutions
4
Agenda - Session 1
Introduction to Value Stream Mapping
Data Collection
Demand/month:
(monthly/weekly forecasts)
Part C =
# of shifts =
8
Demand Chain Solutions
1
Current State Map
Customer
Demand/month:
Part A =
Part B =
Part C =
# of shifts =
Changeover
Downtime FTQ
Current State Map
Step 5: Map the Material Flow
Customer
Supplier
Demand/month:
Part A =
Part B =
Part C =
# of shifts =
2 x/ 2 x/
week day
Shipping
Stamping Welding Assembly
I I I I
1,200 pcs 1,500 pcs 800 pcs 500 pcs
Takt = Takt = Takt = Inventory
C.T. = C.T. = C.T. = Part A =
D.T. = D.T. = 20% D.T. = Part B =
FTQ = FTQ = FTQ = 90% Part C =
C/O Time = 4 hrs. C/O Time = C/O Time = # of shifts =
Lot Size = Lot Size = Lot Size =
# of Shifts # of Shifts # of Shifts
WIP = WIP = WIP =
2 x/
week 2 x/
day
I I I I
1,200 pcs 1,500 pcs 800 pcs 500 pcs
Takt = Takt = Takt = Inventory
C.T. = C.T. = C.T. = Part A = 750 pcs
D.T. = D.T. = 20% D.T. = Part B = 600 pcs
FTQ = FTQ = FTQ = 90% Part C = 1650 pcs
C/O Time = 4 hrs. C/O Time = C/O Time = # of shifts =
Lot Size = Lot Size = Lot Size =
# of Shifts # of Shifts # of Shifts
WIP = 25 pcs. WIP = 60 pcs. WIP = 550 pcs.
2 x/ 2 x/
week day
I I I
800 pcs I
1,200 pcs 1,500 pcs 500 pcs
Takt = Takt = Takt = Inventory
C.T. = C.T. = C.T. = Part A = 750 pcs
D.T. = D.T. = 20% D.T. = Part B = 600 pcs
FTQ = FTQ = FTQ = 90% Part C = 1650 pcs
C/O Time = 4 hrs. C/O Time = C/O Time = # of shifts =
Lot Size = Lot Size = Lot Size =
# of Shifts # of Shifts # of Shifts
WIP = 25 pcs. WIP = 60 pcs. WIP = 550 pcs.
Press Room
Fork Truck
Die Bench
Die Room Die Room
Receiving Shipping
(Remove from
Schedule
I I Board)
Dies Dies
12 shifts 2 shifts
Schedule Board
(Forecast)
Signal Kanban
arriving MAX 50 PCS
Kanban First-In
in batches FIFO First-Out
Flow
Withdrawal
Physical
Kanban
Pull
Production Process
Leveling Kaizen
Kanban
Data Collection
Shipping/Receiving Work-in-process
schedules inventory
Pack sizes at each Overtime per week
process
Demand rates by Process cycle times
process (Takt Time) Number of product
Working hours and variations at each step
breaks
Scrap Batch (lot) sizes
Inventory Points
(location & size) Rework Changeover times
How Operations are Changeover
Downtime
scheduled frequencies
Demand Chain Solutions
Data Collection
Data Box
Tailor the
data box for
your plant’s
needs.
The data
box should
be open
ended to
allow for
additional
attributes.
Demand Chain Solutions
Introduction to Value Stream Mapping
Tools
Scrap
Manufacturing Kaizen
Process Lightning
Burst
Outside
Buffer or
Source/
Safety Stock
Customer
Manual
Information Flow
Data Box
Electronic
I Information Flow
Inventory
Production Kanban
o oo
Truck
Shipment
Withdrawal Kanban
Finished
Goods to Customer
27,000 sec
460 pieces
= 59 sec 59 sec.
59 sec.
59 sec.
8
Demand Chain Solutions
1
Data Collection
How to Calculate Takt Time?
Scheduled Runtime
Takt Time =
Total Customer Requirements
8
Demand Chain Solutions
3
Data Collection
Identify Opportunities for Improvement
?
Demand Chain Solutions
Agenda - Session 1
Introduction to Value Stream Mapping
Data Collection
Summary
• Summary
8
Demand Chain Solutions
1
Future State Map
The Steps
Step 1: Validate Customer Demand
Step 2: Draw the Future State Process Flow
Step 3: Map the Future State Material Flow
Step 4: Map the Future State Information Flow
Step 5: Calculate Total Product Cycle Time
Step 6: Detail Off-Line Activities
Change I
Over
2
Sender
Ass’y
2 I 2 Level
I Fuel Pump No Flow 2
I Inj: Sender ABABA. . .
Ass’y Ass’y
Molding
Attendance Labels Staging
by Truck
10 Tank 4 Ass’y
Stamping I Ass’y Plants 10
Tank 4 Ass’y
Stamping Ass’y card Plants
No Flow
by
Change
Over 12 card
Uptime
7
(Pitch = 14 Units)
Cycle-Time Driven. Batches. Perform to TAKT & Pitch. Zone Maintenance & Fast Response
Produce to Order
METRICS Activity
1999 2000
1ST 2ND 3RD 4TH 1ST 2ND 3RD 4TH
Item Current Target
Establish TAKT & Flow in Tank Ass'y
Total product cycle time
Stamping Changeover Reduction
Parts / Person Hour Reduce Stamping Buffer
Delivery Performance Move Ass'y to Plant 10
Establish TAKT & Flow in Sender Ass'y
Inventory (days)
Pull To Sender Ass'y
Overtime
Uptime Training
Demand Chain Solutions
Future State Map
The Steps
“Do It”
Implement - Implement - Implement
A simple way to
approach the Future
State Map is to begin
by modifying the
Current State Map.
Summary
How will you level the production mix at the pacemaker process?
What increment of work will you consistently release
and take away at the pacemaker process?
What process improvements will be necessary at the value
stream to flow as your future state design specifies?
8
Demand Chain Solutions
4
Consider Key Questions
Where can you use continuous flow processing?
(Batch Process vs. Continuous Flow)
Batch Process
Process
I Process
I Process
“A” “B” “C” Elapsed Time:
60 Minutes
Process
I Process
I Process
“A” “B” “C”
Elapsed Time:
60 Minutes
FIFO
8
Demand Chain Solutions
2
Consider Key Questions
At what single point in the
PC&L production chain will you
schedule production?
Molding Assembly
FIFO
8
Demand Chain Solutions
1 Pacemaker Process
Consider Key Questions
How will you level the production mix at the pacemaker process?
Consideration must be given to level both the mix and overall quantity of
product scheduled for production.
Leveling of the production schedule is a fundamental requirement for the
efficient management of operations
Work- Work-
load load
Time Time
8
Demand Chain Solutions
2
Consider Key Questions
How will you level the production mix at the pacemaker process?
(Continued)
Leveling of the overall production quantity must be supported by the
leveling of the product mix.
Part A & B
Mon. Tue. Wed. Thu . Fri.
Mon. Tue. Wed. Thu
. Fri.
8
Demand Chain Solutions
2
Consider Key Questions
How will you level the production mix at the pacemaker process?
(Continued)
Leveling
of the product mix must be
supported by small lot production.
An effective way
of communicating
the level schedule
to manufacturing
operations can be
through the use of
a load leveling
box.
Macro-Leveling
Mon Tues Wed Thurs Fri Sat Sun
Part
Build
A
Order
Part
B
Part
C
Part
D
Part
E
Part
Card (Part A)
Card (Part A)
Card (Part A)
A
Part
Card (Part B)
Card (Part B)
Card (Part B)
Part
Card (Part C)
Card (Part C)
Card (Part B)
C
Summary
8
Demand Chain Solutions
4
Summary
Objectives Review
Summary