V l St M i V l St M i Value Stream Mapping

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Considerations for Future State Map Takt Time = 25200 sec/400 units = 63 sec/unit Kaizen events combined Molding, Extrusion and Laser Welding ops into one cell with two operators Kaizen combined potting and assembly in one cell, two operators Characterized and re-configured oven to hold 10 trays of 20. Add one/Remove one every 21 minutes. Changed effective ect e cycle time from 5400 secs to 1260 seconds/batch. Went to Kanban scheduling © 2007, Woodside Quality Solutions
Polymeric Bins of Pellets Daily Run Daily E-mail Redi-Coil Steel Wire/Stamped Electrodes Daily Run 2-month forecast Daily E-mail 2-month forecast Production Control Daily Order Future State Map Daily Order 20 20 20 30/60/90-day forecasts Surgistikits 26,400 pcs/mo. 20 parts per Tray. 2 Shifts 2x daily 20 Wire/ Stamped Electrodes (at the welder) Mold Extrude & Weld 1 Assembly and Potting 20 20 1 tray every 21 mins. Curing 20 Shipping Staging Pellets (in the mold hopper) 1 Day Takt = 63 Sec C/T= 61 Sec C/O = 2 min Uptime = 97% 63 Seconds © 2007, Woodside Quality Solutions 1.05 Minutes Takt = 63 Sec C/T= 59 Sec C/O = 3 min Uptime = 96% 59 Seconds 21 Mins C/T = 5400 Secs C/O= 0 Uptime = 100% Capacity: 10 Trays of 20 parts each 5400 Secs 1 tray every 21 mins. .5 Days Production = 1.62 Days Lead Time Processing = 5522 Secs Time
Page 1 and 2: Value Stream Mapping © 2007, Woods
Page 3 and 4: What is “Value” Value = Delta b
Page 5 and 6: First Pass/Final Yield Rework 30 pi
Page 7 and 8: Shewhart - Three Types of Quality 1
Page 9 and 10: Creating Value: The Systems Approac
Page 11 and 12: One “Systems” View Top Manageme
Page 13 and 14: Going Horizontal - The Process Func
Page 15 and 16: Production Control Daily Order 20 2
Page 17 and 18: Value Stream Mapping - Concepts Val
Page 19 and 20: General Lean Principles Workplace S
Page 21 and 22: Lean Actions Identify Value - what
Page 23 and 24: Value Stream Mapping - Definitions
Page 25 and 26: Define Product Family Map one produ
Page 27 and 28: Future State Map Questions to ask w
Page 29 and 30: Some Value Stream Mapping Symbols K
Page 31: Polymeric 55-Gal. Drums of Pellets
Page 35 and 36: High Level Process Maps (SIPOC Diag
Page 37 and 38: Levels of a Process Business Proces
Page 39 and 40: Suppliers Inputs Process Outputs Cu
Page 41 and 42: Hints for creating a high-level lin
Page 43 and 44: Levels of a Process Business Proces
Page 45 and 46: Questions that integrated process m
Page 47 and 48: Detailed Flow Chart Example © 2007
Page 49 and 50: Process Analysis Process Analysis I
Page 51 and 52: The 3% Rule A key concept in cycle
Page 53 and 54: Non-Value Added Work (cont’d) Mov
Page 55 and 56: Employee Interview Process Process
Page 57 and 58: Recap A process is one aspect of a

V l St M i V l St M i Value Stream Mapping

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