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Value stream mapping (current state)

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Value stream mapping is a tool that visually maps the flow of material and information through a production process from raw materials to the customer. It is used to understand sources of waste, highlight decision points, and blueprint improvements. The process involves mapping the current state, then drawing a future state map with proposed changes to eliminate waste. Key steps are selecting a product family, mapping the current state flow including process data, then creating a future state map and work plan.

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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 letsA pencil and paper tool that lets you SEE and UNDERSTAND theyou SEE and UNDERSTAND the flow of material and informationflow of material and information as a product makes its wayas 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 FLOWPRODUCTION 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 seniorsenior mgmt.mgmt. fronfron tt lineline ss ELIMINATIONELIMINATION OF WASTEOF WASTE VALUE STREAMVALUE STREAM IMPROVEMENTIMPROVEMENT focusfocus Value stream improvements driveValue stream improvements drive waste elimination projects.waste elimination projects.
VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS product familyproduct family current-current- statestate drawingdrawing future-future- statestate drawingdrawing work planwork plan
VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS product familyproduct family current-current- statestate drawingdrawing future-future- statestate drawingdrawing work planwork 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 processesprocesses..
PRODUCT FAMILY ASPECTSPRODUCT FAMILY ASPECTS  Manufacturing processManufacturing process  How many part numbersHow 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 familiesRepeat until all product families  are defined.are defined.
PRODUCT MIX MATRIXPRODUCT MIX MATRIX AA BB CC DD EE FF GG XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX PRODUCTSPRODUCTS 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 Hour PART # 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-01 261 0000-002 PRODUCT 2 2500 XXXX-02 125 61 81 159 0000-003 PRODUCT 3 2000 XXXX-03 98 139 293 275 0000-004 PRODUCT 4 7500 XXXX-04 72 64 107 184 0000-005 PRODUCT 5 64000 XXXX-05 95 88 0000-006 PRODUCT 6 61000 XXXX-06 76 48 0000-007 PRODUCT 7 7500 XXXX-07 224 0000-008 PRODUCT 8 24000 XXXX-08 193 0000-009 PRODUCT 9 48000 XXXX-09 73 75 0000-010 PRODUCT 10 61000 XXXX-10 96 61 0000-011 PRODUCT 11 48000 XXXX-11 222 0000-012 PRODUCT 12 24000 XXXX-12 136 0000-013 PRODUCT 13 64000 XXXX-13 236 0000-014 PRODUCT 14 55000 XXXX-14 235 0000-015 PRODUCT 15 48000 XXXX-15 222 0000-016 PRODUCT 16 48000 XXXX-16 136 0000-017 PRODUCT 17 48000 XXXX-17 237 200 0000-018 PRODUCT 18 55000 XXXX-18 90 93 0000-019 PRODUCT 19 55000 XXXX-19 292 186 0000-020 PRODUCT 20 64000 XXXX-20 254 333 834500 Part 2 - Annual Hours per Machine PART # 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 0 0000-002 PRODUCT 2 2500 XXXX-02 20 41 31 16 0 0 0 0 0 0 0000-003 PRODUCT 3 2000 XXXX-03 20 14 7 7 0 0 0 0 0 0 0000-004 PRODUCT 4 7500 XXXX-04 104 117 70 41 0 0 0 0 0 0 0000-005 PRODUCT 5 64000 XXXX-05 674 727 0 0 0 0 0 0 0 0 0000-006 PRODUCT 6 61000 XXXX-06 803 1271 0 0 0 0 0 0 0 0 0000-007 PRODUCT 7 7500 XXXX-07 33 0 0 0 0 0 0 0 0 0 0000-008 PRODUCT 8 24000 XXXX-08 124 0 0 0 0 0 0 0 0 0 0000-009 PRODUCT 9 48000 XXXX-09 0 0 0 0 658 640 0 0 0 0 0000-010 PRODUCT 10 61000 XXXX-10 0 0 0 0 635 1000 0 0 0 0 0000-011 PRODUCT 11 48000 XXXX-11 0 0 0 0 216 0 0 0 0 0 0000-012 PRODUCT 12 24000 XXXX-12 0 0 0 0 176 0 0 0 0 0 0000-013 PRODUCT 13 64000 XXXX-13 0 0 0 0 271 0 0 0 0 0 0000-014 PRODUCT 14 55000 XXXX-14 0 0 0 0 234 0 0 0 0 0 0000-015 PRODUCT 15 48000 XXXX-15 0 0 0 0 216 0 0 0 0 0 0000-016 PRODUCT 16 48000 XXXX-16 0 0 0 0 353 0 0 0 0 0 0000-017 PRODUCT 17 48000 XXXX-17 0 0 0 0 203 0 240 0 0 0 0000-018 PRODUCT 18 55000 XXXX-18 0 0 0 0 611 0 591 0 0 0 0000-019 PRODUCT 19 55000 XXXX-19 0 0 0 0 188 0 296 0 0 0 0000-020 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 namesCustomer 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 MonthlMonthl yy 10/box10/box 10/box10/box 10/box10/box 10/box10/box Product Family:Product Family: TiltTilt MechanismsMechanisms
VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS product familyproduct family current-current- statestate drawingdrawing future-future- statestate drawingdrawing work planwork 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 bothWalk 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, usingDo a detailed walk-through, using a stop watch to collect actuala stop watch to collect actual times 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, you understand it  Focus on flow, not a computer  Fixing your own mistakes fine- tunes skills
MAP LAYOUT GEOGRAPHYMAP LAYOUT GEOGRAPHY 1111 1717 Customer Info. Process Flow Information Supplier Info. Production Control Info. Time Line
START WITH THE CUSTOMERSTART WITH THE CUSTOMER Customer 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 tray20 units per tray • Operates on two shiftsOperates on two shifts • 1 truck per day1 truck per day State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts Icons:Icons:
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 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 T PresPres ss Weld IIWeld II Weld IWeld I Assembly IAssembly I Assembly IIAssembly II WeldingWelding InspectionInspection AreaArea PRESS DEPT.PRESS DEPT. WELDING DEPT.WELDING DEPT. SHIPPINGSHIPPING ASSEMBLY DEPT.ASSEMBLY DEPT. Steel CoilSteel Coil StorageStorage Stamped PartsStamped Parts StorageStorage FinishedFinished GoodsGoods StorageStorage ACME STAMPING FACTORY LAYOUTACME STAMPING FACTORY LAYOUT = WIP in Baskets= WIP in Baskets = Finished Goods in Trays= Finished Goods in Trays Welded PartsWelded Parts StorageStorage FINALFINAL II NN SS PP EE CC TT II OO NN
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?
1x Daily 1x Daily SHIPPING Staging I 2700 L2700 L 1440 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 Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts SHIPPING I 2700 L 1440 R Staging 1x Daily
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 PROCESS Icons:Icons: ASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift I 1200 L1200 L 640 R640 R I
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift I 1200 L 640 R I 2700 L 1440 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 PROCESS Icons:Icons: ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift I 1600 L1600 L 850 R850 R I
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 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 PROCESS Icons:Icons: S.WELD #2 1 C/T = 46 seconds C/O = 10 min. Uptime = 80% 2 Shifts 27,600 sec/shift I 1100 L1100 L 600 R600 R I
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 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 PROCESS Icons:Icons: S.WELD #1 1 C/T = 39 seconds C/O = 10 min. Uptime = 100% 2 Shifts 27,600 sec/shift I 4600 L4600 L 2400 R2400 R I
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 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 PROCESS Icons:Icons: STAMPING C/T = 1 second C/O = 1 hour Uptime = 85% EPE = 2 weeks 27,600 sec/shift I CoilsCoils 5 days5 days 200 T
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging4600 L 2400 R STAMPING I Coils 5 days C/T = 1 seconds C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weeks I 200 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 Michigan Steel Co. 500 ft. coils
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift STAMPING I Coils 5 days C/T = 1 seconds C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weks I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging200 T Michigan Steel Co. 500 ft. coils Tues. + Thurs. This is the Material Flow IN Door Door to Door Value Stream OUT Door
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 FLOW Icons:Icons: PRODUCTION CONTROL MRP Daily Order Weekly Schedule
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift STAMPING I Coils 5 days C/T = 1 seconds C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weeks I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging200 T Michigan Steel Co. 500 ft. coils Tues. + Thurs. PRODUCTION CONTROL MRP Daily Order 30/60/90 day Forecasts Weekly Release 6-week Forecasts Weekly Schedule Daily Ship Schedule
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 Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift STAMPING I Coils 5 days C/T = 1 second C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weeks I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging200 T Michigan Steel Co. 500 ft. coils Tues. + Thurs. PRODUCTION CONTROL MRP Daily Order 30/60/90 day Forecasts Weekly Release 6-week Forecasts Weekly Schedule Daily Ship Schedule 1 second 39 sec. 62 sec. 40 sec. Value Added Time = 188 sec.46 sec. 5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days Production Leadtime 23.6 days=
IDENTIFY OPPORTUNITIESIDENTIFY OPPORTUNITIES • The Current State Map shows what isThe Current State Map shows what is happening “right now.”happening “right now.” • It identifies wasteful steps and slow-downIt identifies wasteful steps and slow-down causes.causes. • It helps visualize how operations can beIt helps visualize how operations can be combined to “flow” production.combined to “flow” production. • It lets you see where “pull” systems makeIt 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 impactIt shows how the improvements impact thethe value streamvalue stream..
CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift STAMPING I Coils 5 days C/T = 1 second C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weeks I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging200 T Michigan Steel Co. 500 ft. coils Tues. + Thurs. PRODUCTION CONTROL MRP Daily Order 30/60/90 day Forecasts Weekly Release 6-week Forecasts Weekly Schedule Daily Ship Schedule 1 second 39 sec. 62 sec. 40 sec. Value Added Time = 188 sec.46 sec. 5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days Production Leadtime 23.6 days= “flow” cell pullpull pull
TWI CASE STUDYTWI CASE STUDY • Read through the TWI Case StudyRead through the TWI Case Study hand out information.hand out information. • Draw a Current State Map, using theDraw a Current State Map, using the tools and techniques described intools and techniques described in this section.this section. • Return to class prepared to discussReturn to class prepared to discuss your map and why you drew it thatyour map and why you drew it that way.way.
C/T = oper 10 sec mach 30 sec C/O = 15 min - 1 hr Uptime 90% TWI CURRENT STATE MAP OE + Aftermarket Customers 24,000 pcs/mo 240 P/N’s 25-200 pc orders Box = 5 pcs Various Daily SHIPPINGASSEMBLY 6 C/T = 195 sec total C/O = 10 min Uptime = 100% 3 end fittings 6 combos/rod DEFLASH 1 WELD #2 1 WELD #1 5 days 1 MACHINING I Forgings 20 days I I 3 days I 3 days I 6 days I 4 days Staging 2x Monthly Orders 60 days out Orders Daily Priorities Daily Ship Schedule 30 sec. 30 sec. 2 days 30 sec. 20 days 5 days 3 days 3 days 5 days 6 days Outside Painter I 5 days Daily Daily Michigan Steel Co. CUT I Rods 20 days C/T = 15 seconds C/O = 15-60 min. Uptime = 100% 1 4 days C/T = oper 10 sec mach 30 sec C/O = 15 min - 1 hr Uptime 80% C/T = oper 10 sec mach 30 sec C/O = 15 min - 1 hr Uptime 100% LT = 48 days I 2 days Indianna Castings Forgings 12 week LT Rods 16 week LT Orders Shop Orders To Weld Area Supervisor PRODUCTION CONTROL 195 sec. 4 days I Size Change 2 weeks out C/T = 30 seconds 2 pieces/assembly C/O = 2 hours Uptime = 85% 60 sec. VA = 345 sec

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Value stream mapping (current state)

  • 1. Value Stream MappingValue Stream Mapping
  • 2. 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.
  • 3. VALUE STREAM MAPPINGVALUE STREAM MAPPING A pencil and paper tool that letsA pencil and paper tool that lets you SEE and UNDERSTAND theyou SEE and UNDERSTAND the flow of material and informationflow of material and information as a product makes its wayas a product makes its way through the value stream.through the value stream.
  • 4. • 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
  • 6. • 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.
  • 7. MAPPING THE ‘BIG’ PICTUREMAPPING THE ‘BIG’ PICTURE seniorsenior mgmt.mgmt. fronfron tt lineline ss ELIMINATIONELIMINATION OF WASTEOF WASTE VALUE STREAMVALUE STREAM IMPROVEMENTIMPROVEMENT focusfocus Value stream improvements driveValue stream improvements drive waste elimination projects.waste elimination projects.
  • 8. VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS product familyproduct family current-current- statestate drawingdrawing future-future- statestate drawingdrawing work planwork plan
  • 9. VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS product familyproduct family current-current- statestate drawingdrawing future-future- statestate drawingdrawing work planwork plan product familyproduct family
  • 10. 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 processesprocesses..
  • 11. PRODUCT FAMILY ASPECTSPRODUCT FAMILY ASPECTS  Manufacturing processManufacturing process  How many part numbersHow many part numbers  ““Spin-off” TestSpin-off” Test PROCESSPROCESS
  • 12. 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 familiesRepeat until all product families  are defined.are defined.
  • 13. PRODUCT MIX MATRIXPRODUCT MIX MATRIX AA BB CC DD EE FF GG XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX PRODUCTSPRODUCTS 1 2 3 4 5 6 7 81 2 3 4 5 6 7 8 Assembly Steps & EquipmentAssembly Steps & Equipment
  • 14. MACHINE LOADING ANALYSIS Part 1 - Pieces per Hour PART # 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-01 261 0000-002 PRODUCT 2 2500 XXXX-02 125 61 81 159 0000-003 PRODUCT 3 2000 XXXX-03 98 139 293 275 0000-004 PRODUCT 4 7500 XXXX-04 72 64 107 184 0000-005 PRODUCT 5 64000 XXXX-05 95 88 0000-006 PRODUCT 6 61000 XXXX-06 76 48 0000-007 PRODUCT 7 7500 XXXX-07 224 0000-008 PRODUCT 8 24000 XXXX-08 193 0000-009 PRODUCT 9 48000 XXXX-09 73 75 0000-010 PRODUCT 10 61000 XXXX-10 96 61 0000-011 PRODUCT 11 48000 XXXX-11 222 0000-012 PRODUCT 12 24000 XXXX-12 136 0000-013 PRODUCT 13 64000 XXXX-13 236 0000-014 PRODUCT 14 55000 XXXX-14 235 0000-015 PRODUCT 15 48000 XXXX-15 222 0000-016 PRODUCT 16 48000 XXXX-16 136 0000-017 PRODUCT 17 48000 XXXX-17 237 200 0000-018 PRODUCT 18 55000 XXXX-18 90 93 0000-019 PRODUCT 19 55000 XXXX-19 292 186 0000-020 PRODUCT 20 64000 XXXX-20 254 333 834500 Part 2 - Annual Hours per Machine PART # 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 0 0000-002 PRODUCT 2 2500 XXXX-02 20 41 31 16 0 0 0 0 0 0 0000-003 PRODUCT 3 2000 XXXX-03 20 14 7 7 0 0 0 0 0 0 0000-004 PRODUCT 4 7500 XXXX-04 104 117 70 41 0 0 0 0 0 0 0000-005 PRODUCT 5 64000 XXXX-05 674 727 0 0 0 0 0 0 0 0 0000-006 PRODUCT 6 61000 XXXX-06 803 1271 0 0 0 0 0 0 0 0 0000-007 PRODUCT 7 7500 XXXX-07 33 0 0 0 0 0 0 0 0 0 0000-008 PRODUCT 8 24000 XXXX-08 124 0 0 0 0 0 0 0 0 0 0000-009 PRODUCT 9 48000 XXXX-09 0 0 0 0 658 640 0 0 0 0 0000-010 PRODUCT 10 61000 XXXX-10 0 0 0 0 635 1000 0 0 0 0 0000-011 PRODUCT 11 48000 XXXX-11 0 0 0 0 216 0 0 0 0 0 0000-012 PRODUCT 12 24000 XXXX-12 0 0 0 0 176 0 0 0 0 0 0000-013 PRODUCT 13 64000 XXXX-13 0 0 0 0 271 0 0 0 0 0 0000-014 PRODUCT 14 55000 XXXX-14 0 0 0 0 234 0 0 0 0 0 0000-015 PRODUCT 15 48000 XXXX-15 0 0 0 0 216 0 0 0 0 0 0000-016 PRODUCT 16 48000 XXXX-16 0 0 0 0 353 0 0 0 0 0 0000-017 PRODUCT 17 48000 XXXX-17 0 0 0 0 203 0 240 0 0 0 0000-018 PRODUCT 18 55000 XXXX-18 0 0 0 0 611 0 591 0 0 0 0000-019 PRODUCT 19 55000 XXXX-19 0 0 0 0 188 0 296 0 0 0 0000-020 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
  • 15. PRODUCT FAMILY ASPECTSPRODUCT FAMILY ASPECTS  ““Spin-off” TestSpin-off” Test  Manufacturing processManufacturing process  How many part numbersHow many part numbers  Customer namesCustomer names  Customer volumesCustomer volumes  Delivery frequencyDelivery frequency PROCESSPROCESS CUSTOMERCUSTOMER
  • 16. 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 MonthlMonthl yy 10/box10/box 10/box10/box 10/box10/box 10/box10/box Product Family:Product Family: TiltTilt MechanismsMechanisms
  • 17. VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS product familyproduct family current-current- statestate drawingdrawing future-future- statestate drawingdrawing work planwork plan current-current- statestate drawingdrawing
  • 18. 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 bothWalk 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, usingDo a detailed walk-through, using a stop watch to collect actuala stop watch to collect actual times and counting inventory.times and counting inventory. 6.6. Draw by hand in pencil.Draw by hand in pencil.
  • 19. WHY IN PENCIL, BY HAND?WHY IN PENCIL, BY HAND?  No delays  You do it, you understand it  Focus on flow, not a computer  Fixing your own mistakes fine- tunes skills
  • 20. MAP LAYOUT GEOGRAPHYMAP LAYOUT GEOGRAPHY 1111 1717 Customer Info. Process Flow Information Supplier Info. Production Control Info. Time Line
  • 21. START WITH THE CUSTOMERSTART WITH THE CUSTOMER Customer 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 tray20 units per tray • Operates on two shiftsOperates on two shifts • 1 truck per day1 truck per day State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts Icons:Icons:
  • 22. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts
  • 23. 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
  • 24. 200 T200 T PresPres ss Weld IIWeld II Weld IWeld I Assembly IAssembly I Assembly IIAssembly II WeldingWelding InspectionInspection AreaArea PRESS DEPT.PRESS DEPT. WELDING DEPT.WELDING DEPT. SHIPPINGSHIPPING ASSEMBLY DEPT.ASSEMBLY DEPT. Steel CoilSteel Coil StorageStorage Stamped PartsStamped Parts StorageStorage FinishedFinished GoodsGoods StorageStorage ACME STAMPING FACTORY LAYOUTACME STAMPING FACTORY LAYOUT = WIP in Baskets= WIP in Baskets = Finished Goods in Trays= Finished Goods in Trays Welded PartsWelded Parts StorageStorage FINALFINAL II NN SS PP EE CC TT II OO NN
  • 25. 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?
  • 26. 1x Daily 1x Daily SHIPPING Staging I 2700 L2700 L 1440 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
  • 27. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts SHIPPING I 2700 L 1440 R Staging 1x Daily
  • 28. 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 PROCESS Icons:Icons: ASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift I 1200 L1200 L 640 R640 R I
  • 29. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift I 1200 L 640 R I 2700 L 1440 R Staging
  • 30. 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 PROCESS Icons:Icons: ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift I 1600 L1600 L 850 R850 R I
  • 31. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging
  • 32. 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 PROCESS Icons:Icons: S.WELD #2 1 C/T = 46 seconds C/O = 10 min. Uptime = 80% 2 Shifts 27,600 sec/shift I 1100 L1100 L 600 R600 R I
  • 33. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging
  • 34. 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 PROCESS Icons:Icons: S.WELD #1 1 C/T = 39 seconds C/O = 10 min. Uptime = 100% 2 Shifts 27,600 sec/shift I 4600 L4600 L 2400 R2400 R I
  • 35. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging
  • 36. 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 PROCESS Icons:Icons: STAMPING C/T = 1 second C/O = 1 hour Uptime = 85% EPE = 2 weeks 27,600 sec/shift I CoilsCoils 5 days5 days 200 T
  • 37. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging4600 L 2400 R STAMPING I Coils 5 days C/T = 1 seconds C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weeks I 200 T STAMPING
  • 38. 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 Michigan Steel Co. 500 ft. coils
  • 39. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift STAMPING I Coils 5 days C/T = 1 seconds C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weks I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging200 T Michigan Steel Co. 500 ft. coils Tues. + Thurs. This is the Material Flow IN Door Door to Door Value Stream OUT Door
  • 40. 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 FLOW Icons:Icons: PRODUCTION CONTROL MRP Daily Order Weekly Schedule
  • 41. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift STAMPING I Coils 5 days C/T = 1 seconds C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weeks I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging200 T Michigan Steel Co. 500 ft. coils Tues. + Thurs. PRODUCTION CONTROL MRP Daily Order 30/60/90 day Forecasts Weekly Release 6-week Forecasts Weekly Schedule Daily Ship Schedule
  • 42. 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
  • 43. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift STAMPING I Coils 5 days C/T = 1 second C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weeks I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging200 T Michigan Steel Co. 500 ft. coils Tues. + Thurs. PRODUCTION CONTROL MRP Daily Order 30/60/90 day Forecasts Weekly Release 6-week Forecasts Weekly Schedule Daily Ship Schedule 1 second 39 sec. 62 sec. 40 sec. Value Added Time = 188 sec.46 sec. 5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days Production Leadtime 23.6 days=
  • 44. IDENTIFY OPPORTUNITIESIDENTIFY OPPORTUNITIES • The Current State Map shows what isThe Current State Map shows what is happening “right now.”happening “right now.” • It identifies wasteful steps and slow-downIt identifies wasteful steps and slow-down causes.causes. • It helps visualize how operations can beIt helps visualize how operations can be combined to “flow” production.combined to “flow” production. • It lets you see where “pull” systems makeIt 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 impactIt shows how the improvements impact thethe value streamvalue stream..
  • 45. CURRENT STATE MAPCURRENT STATE MAP State Street Assembly 18,400 pcs/mo - 12,000 LH - 6,400 RH Tray = 20 pcs 2 shifts 1x Daily SHIPPINGASSEMBLY #2 1 C/T = 40 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift ASSEMBLY #1 1 C/T = 62 seconds C/O = 0 Uptime = 100% 2 Shifts 27,600 sec/shift S. WELD #2 1 C/T = 46 seconds C/O = 10 minutes Uptime = 80% 2 Shifts 27,600 sec/shift S. WELD #1 4600 L 2400 R 1 C/T = 39 seconds C/O = 10 minutes Uptime = 100% 2 Shifts 27,600 sec/shift STAMPING I Coils 5 days C/T = 1 second C/O = 1 hour Uptime = 85% 27,600 sec./shift EPE = 2 weeks I I 1100 L 600 R I 1600 L 850 R I 1200 L 640 R I 2700 L 1440 R Staging200 T Michigan Steel Co. 500 ft. coils Tues. + Thurs. PRODUCTION CONTROL MRP Daily Order 30/60/90 day Forecasts Weekly Release 6-week Forecasts Weekly Schedule Daily Ship Schedule 1 second 39 sec. 62 sec. 40 sec. Value Added Time = 188 sec.46 sec. 5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days Production Leadtime 23.6 days= “flow” cell pullpull pull
  • 46. TWI CASE STUDYTWI CASE STUDY • Read through the TWI Case StudyRead through the TWI Case Study hand out information.hand out information. • Draw a Current State Map, using theDraw a Current State Map, using the tools and techniques described intools and techniques described in this section.this section. • Return to class prepared to discussReturn to class prepared to discuss your map and why you drew it thatyour map and why you drew it that way.way.
  • 47. C/T = oper 10 sec mach 30 sec C/O = 15 min - 1 hr Uptime 90% TWI CURRENT STATE MAP OE + Aftermarket Customers 24,000 pcs/mo 240 P/N’s 25-200 pc orders Box = 5 pcs Various Daily SHIPPINGASSEMBLY 6 C/T = 195 sec total C/O = 10 min Uptime = 100% 3 end fittings 6 combos/rod DEFLASH 1 WELD #2 1 WELD #1 5 days 1 MACHINING I Forgings 20 days I I 3 days I 3 days I 6 days I 4 days Staging 2x Monthly Orders 60 days out Orders Daily Priorities Daily Ship Schedule 30 sec. 30 sec. 2 days 30 sec. 20 days 5 days 3 days 3 days 5 days 6 days Outside Painter I 5 days Daily Daily Michigan Steel Co. CUT I Rods 20 days C/T = 15 seconds C/O = 15-60 min. Uptime = 100% 1 4 days C/T = oper 10 sec mach 30 sec C/O = 15 min - 1 hr Uptime 80% C/T = oper 10 sec mach 30 sec C/O = 15 min - 1 hr Uptime 100% LT = 48 days I 2 days Indianna Castings Forgings 12 week LT Rods 16 week LT Orders Shop Orders To Weld Area Supervisor PRODUCTION CONTROL 195 sec. 4 days I Size Change 2 weeks out C/T = 30 seconds 2 pieces/assembly C/O = 2 hours Uptime = 85% 60 sec. VA = 345 sec