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Introduction to mapping Creating a Current State Map Introduction To Lean Techniques Creating a Future State Map Using a Map as a basis for Tactical Implementation.

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Presentation on theme: "Introduction to mapping Creating a Current State Map Introduction To Lean Techniques Creating a Future State Map Using a Map as a basis for Tactical Implementation."— Presentation transcript:

1 Introduction to mapping Creating a Current State Map Introduction To Lean Techniques Creating a Future State Map Using a Map as a basis for Tactical Implementation Planning AGENDA Value Stream Mapping

2 1. What are the customer requirements 2. How to apply Continuous Flow Processing 3. Which process is the pacemaker 4. How to control upstream processes 5. What size supermarkets (shop stock) are required 6. Is it sequential or fill-up pull 7. Where to level production 8. At what frequency will kanban be released 9. What further improvements can be made THE 9 KEY QUESTIONS : Future State Value Stream Mapping

3 THE 7 STEPS 1. Customer Requirements 2. Draw Process Steps 3. Process Data 4. Inventory 5. Material Flow: Supplier to Manufacturer & Manufacturer to Customer 6. Information Driving Flow & Internal Material Flow 7. Manufacturing Lead Time & Processing Time Creating a Future State Value Stream Map

4 Ref.ppt FIFO abc Production Control I OXOX Supermarket Supermarket with Prod Card Supermarket with Prod Card & Withdrawal card First In First Out sequence flow Kanban Post Inventory Pull Symbol Information System VSM Symbols Production Control Electronic information flow Level loading Production Signal Kanban Min & Max Manual Information flow Kaizen lightening burst Truck Shipment Mon + Wed PUSH arrow 300 pieces 1Day CHANGEOVER XYZ corporation Outside sources Sequenced-Pull Ball Icons for use in Future State

5 Go to white board and change current state to future state. Ask the delegates to draw it with you

6 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Assembly # 2 Assembly # 1 Spot weld # 2 Spot weld # 1 Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x Cycle time= 39 minute Change over=10 min. Uptime =100% 1 x 10 T Cycle time= 46 minute Change over=10 min. Uptime =80% 1 x Cycle time= 62 minute Change over=0 min. Uptime =100% 1 x Cycle time= 40 minute Change over=0 min. Uptime =100% 1 x IIII 5 days 150 A1 24 A2 II 42 A1 6 A2 16 A1 18 A2 42 A1 6 A2 27 A1 14 A2 Coils r us 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day 10.9 days 2.1 days 3 days2.6 days 5 days Production Lead Time = 26.6 days Processing time = 188 mins 1 minute39 minute46 minute62 minute40 minute 3 days Current State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

7 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Assembly # 1 Assembly # 2 Spot weld # 2 Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x Cycle time= 39 minute Change over=10 min. Uptime =100% 1 x 10 T Cycle time= 46 minute Change over=10 min. Uptime =80% 1 x Cycle time= 62 minute Change over=0 min. Uptime =100% 1 x Cycle time= 40 minute Change over=0 min. Uptime =100% 1 x IIII 5 days 150 A1 24 A2 II 42 A1 6 A2 16 A1 8 A2 42 A1 6 A2 27 A1 14 A2 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day 10.9 days 3 days 2.1 days 3 days2.6 days 5 days Production Lead Time = 26.6 days Processing time = 188 mins Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins x 1 minute39 minute46 minute62 minute40 minute Coils r us Add Takt Calculation Slug Brackets Stamping Currents State Map Date : 1 x Daily

8 StampSW 1SW 2Assy. 1Assy. 2 1 min. 39 min. 46 min. 62 min. 40 min min. Takt DRAW ON FLIP CHART Where is Continuous Flow Possible?

9 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Assembly # 1 Assembly # 2 Spot weld # 2 Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x Cycle time= 39 minute Change over=10 min. Uptime =100% 1 x 10 T Cycle time= 46 minute Change over=10 min. Uptime =80% 1 x Cycle time= 62 minute Change over=0 min. Uptime =100% 1 x Cycle time= 40 minute Change over=0 min. Uptime =100% 1 x IIII 5 days 150 A1 24 A2 II 200 A1 6 A2 16 A1 8 A2 42 A1 6 A2 27 A1 14 A2 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day 10.9 days 3 days 2.1 days 3 days2.6 days 5 days Production Lead Time = 26.6 days Processing time = 188 mins Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

10 StampSW 1SW 2Assy. 1Assy. 2 1 min. 39 min. 46 min. 62 min. 40 min. DRAW ON FLIP CHART 57.5 min. Takt Where is Continuous Flow Possible?

11 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Assembly # 1 Assembly # 2 Spot weld # 2 Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x Cycle time= 39 minute Change over=10 min. Uptime =100% 1 x 10 T Cycle time= 46 minute Change over=10 min. Uptime =80% 1 x Cycle time= 62 minute Change over=0 min. Uptime =100% 1 x Cycle time= 40 minute Change over=0 min. Uptime =100% 1 x IIII 5 days 150 A1 24 A2 II 200 A1 6 A2 16 A1 8 A2 42 A1 6 A2 27 A1 14 A2 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day 10.9 days 3 days 2.1 days 3 days2.6 days 5 days Production Lead Time = 26.6 days Processing time = 188 mins Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

12 StampSW 1SW 2Assy. 1Assy. 2 1 min. 39 min. 46 min. 62 min. 40 min. DRAW ON FLIP CHART 57.5 min. Takt Where is Continuous Flow Possible?

13 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Assembly # 1 Assembly # 2 Spot weld # 2 Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x Cycle time= 39 minute Change over=10 min. Uptime =100% 1 x 10 T Cycle time= 46 minute Change over=10 min. Uptime =80% 1 x Cycle time= 62 minute Change over=0 min. Uptime =100% 1 x Cycle time= 40 minute Change over=0 min. Uptime =100% 1 x IIII 5 days 150 A1 24 A2 II 200 A1 6 A2 16 A1 8 A2 42 A1 6 A2 27 A1 14 A2 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day 10.9 days 3 days 2.1 days 3 days2.6 days 5 days Production Lead Time = 26.6 days Processing time = 188 mins Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

14 x Ideal No. Of Operators= Total Work Content Takt Time e.g. Ideal No. Of Operators= 187 minutes of work 57.5 minutes Takt = 3.25 operators = 4 = target of 3 Where is Continuous Flow Possible?

15 55 (55 X 3) + 22 = 187 minutes DRAW ON FLIP CHART Takt Cycle Time Stamp 1 min. SW 1 SW 2 Assy. 1 Assy min. SW 2 30 min. 16 min. 25 min. Assy min. 18 min. Assy min min. Takt Where is Continuous Flow Possible?

16 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Assembly # 1 Assembly # 2 Spot weld # 2 Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x Cycle time= 39 minute Change over=10 min. Uptime =100% 1 x 10 T Cycle time= 46 minute Change over=10 min. Uptime =80% 1 x Cycle time= 62 minute Change over=0 min. Uptime =100% 1 x Cycle time= 40 minute Change over=0 min. Uptime =100% 1 x IIII 5 days 150 A1 24 A2 II 200 A1 6 A2 16 A1 8 A2 42 A1 6 A2 27 A1 14 A2 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day 10.9 days 3 days 2.1 days 3 days2.6 days 5 days Production Lead Time = 26.6 days Processing time = 188 mins Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

17 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts ShippingStamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x I 5 days 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days Weld+ assy. Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Target 3 Ops Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

18 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts ShippingStamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x I 5 days 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 Weld+ assy. Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Target 3 Ops Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

19 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts ShippingStamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x I 5 days 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 1 Weld+ assy. Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Target 3 Ops Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

20 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts ShippingStamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x I 5 days 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 batch Weld+ assy. Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Target 3 Ops Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

21 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts ShippingStamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x I 5 days 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 batch 1.5 days delivery trays Weld+ assy. Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Target 3 Ops Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

22 1 1 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Weld+ assy. Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x I 5 days 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily Shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 batch 1.5 days 1 stage delivery trays Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Target 3 Ops Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

23 1 1 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Weld+ assy. Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x I 5 days 500 ft coils Tuesday and Thursday Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast Weekly fax MRP Weekly plan Daily Shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 batch 1.5 days 1 stage OOXXOOXX Pitch = 57.5 mins delivery trays Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Target 3 Ops Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

24 1 1 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Weld+ assy. Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x 500 ft coils Daily Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast MRP Weekly plan Daily Shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 batch 1.5 days 1 stage OOXXOOXX Pitch = 57.5mins 1.5 days delivery trays Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Target 3 Ops Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

25 1 1 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Weld+ assy. Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 4 x 500 ft coils Daily Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast MRP Daily Shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 batch 1.5 days 1 stage OOXXOOXX 1.5 days 1.5 days 1 min 1.5 days 165 min 2 days 5 days 166 minutes delivery trays Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Pitch = 57.5 mins Target 3 Ops Coils r us Drawing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

26 Delegates to design own future state map Value Stream Mapping

27 Current State MapFuture State Map Gap Analysis …... WHERE WILL YOU START ? Developing an Improvement Plan

28 1 1 Customer. Pack size = pieces/ month 200 A1 120 A2 2 shifts Shipping Weld+ assy. Stamping Cycle time= 1 minute Change over=1 hour Uptime =85% 1 x 10 T TT= 60 minute C/T=55 min 3 x F.A.L. 500 ft coils Daily Production Planning 30/ 60/ 90 day forecast Daily expedite 6 week forecast MRP Daily Shipping plan 16 pieces/ day Work content To 55 min. SW C/O SW 2 uptime 2 days 1 batch 1.5 days 1 stage OOXXOOXX 1.5 days 1.5 days 1 min 1.5 days 165 min 2 days 5 days 166 minutes Supplier loop Stamping loop Pacemaker loop delivery trays Takt = 2(480-20)minutes = 57.5 mins 16 pieces Pitch = 57.5 mins x 1 pieces = 57.5 mins Pitch = 57.5 mins Target 3 Ops Dividing a Future State Map Slug Brackets Stamping Currents State Map Date : 1 x Daily

29 Introduction to mapping Creating a Current State Map Practical Exercise Introduction To Lean Techniques Creating a Future State Map Using a Map as a basis for Tactical Implementation Planning AGENDA Value Stream Mapping

30 To set the team direction To show a relevant level of detail to those concerned - NB. each loop will have its own execution schedules within the implementation plan To encourage regular reviews for signs of QCD problems - slippage's, early deliveries, continued ownership To formalise commitment from key people: Facility ManagerValue stream manager The Unions Manufacturing Engineering Maintenance Process Engineering Purchasing The key elements of a Value Streams Implementation plan are shown in the following example. Why Have a Formal Plan to Achieve the future State?

31 Example - Tactical Implementation Plan (T.I.P.) 5C Activity Category Level 1 Activity Level 2 Detailed Actions Timebased Schedule of activities Type of TIP and Model Line Responsible People

32 Collect data across a value stream. Use the 7 steps to draw a current state Value Stream Map. Use the 9 questions and 7 steps to draw a future state Value Stream Map. Identify your Material/Information loops. Decide the order to tackle the loops. Write the Tactical Implementation Plan Set objectives for each loop as required to achieve the future state Set measurable goals for each objective Use the 9 questions within each loop to set an order of work Set milestones and write up the plan Get formal agreement from all concerned The leader of each work stream should produce their own execution schedule showing how to achieve each goal by its milestone. Summary

33 Introduction to mapping Creating a Current State Map Practical Exercise Introduction To Lean Techniques Creating a Future State Map Using a Map as a basis for Tactical Implementation Planning AGENDA Value Stream Mapping

34 Summary Just do it !


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