Value Stream Map

Define phase

Charter

Problem Statement;

The Acme Stamping Company are unable to meet the demand for bracket subassemblies to their customers.

Customers/Stakeholders

State Street Vehicle Assembly plant

Car owners

Dealerships

Coil Steel Suppliers

Employees

What is important to these customers?

A bracket which meets specification and is received in a timely manner to prevent delays in assembly and delivery of vehicles.

Goal of the project:

To develop a process that meets the demand of the customer and be on time.

Scope Statement

The process to be evaluated begins with the ordering of coil material and ends with the delivery at the customer site.

Benefits

The customer will continue to buy from us which allows us to stay in business.

Potential risks

Coil supplier unable to meet our demand

Workers unwilling to modify work flow

Measure phase

Measure Report

Customer requirements

  • 18400 brackets per month
  • 12000 of LH
  • 6400 of RH
  • Customer plant operates 2 shifts per day
  • Palletized returnable tray packaging with 20 brackets in a tray and up to 10 trays per pallet
  • The customer orders in multiples of trays
  • Only one daily shipment to the assembly plant by truck

Work time

  • 20 days in a month
  • 2 shifts operation in all production departments
  • Eight hours each shift, overtime as necessary
  • Two 10 min breaks per shift
  • Manual processes stop during breaks
  • Unpaid lunch

Production processes

  • Acme’s process for this product family involves
  • Stamping a part
  • Welding the part
  • Assembling the part
  • Parts are staged
  • Parts are shipped, once a day
  • Switching between LH and RH types takes 1 hour for changeover in stamping
  • Changeover in welding takes 10 min
  • Steel coils are supplied by Michigan steel co.
  • Steel coil deliveries are made to Acme on Tuesdays and Thursdays

Acme Production Control department

  • State Street’s 90/60/30 day forecast is entered into the MRP
  • Acme issues a 6-week forecast to Michigan Steel via MRP
  • Secures coil steel by weekly Faxed order released to Michigan Steel
  • Receives daily firm order from State Street
  • Generates MRP based weekly departmental requirements based upon customer order, WIP inventory levels, F/G inventory levels and anticipated scrap and downtime
  • Issues weekly build schedules to Stamping, Welding and Assembly processes
  • Issues daily shipping schedule to shipping department

Process Information

  1. Stamping
  2. The press makes parts for many Acme products
  3. Automated 200 ton press with automated feed
  4. Cycle Time: 1 second
  5. Changeover time: 1 hour
  6. Machine reliability: 85%
  7. Observed Inventory
  8. 5 days of coils before stamping
  9. 4600 of LH stampings
  10. 2400 of RH stampings
  11. Spot-Weld Workstation I
  12. Dedicated to this process
  13. Manual process with one operator
  14. Cycle time: 39 seconds
  15. Changeover time: 10 minutes
  16. Reliability: 100%
  17. Observed Inventory
  18. 1100 pieces of LH
  19. 600 pieces of RH
  20. Spot-Weld Workstation II
  21. Dedicated to this line
  22. Manual process with one operator
  23. Cycle time: 46 seconds
  24. Reliability 80%
  25. Changeover: 10 minutes
  26. Observed Inventory
  27. 1600 pieces of LH
  28. 850 pieces of RH
  29. Assembly Workstation I
  30. Dedicated to this line
  31. Manual process with one operator
  32. Cycle time: 62 seconds
  33. Reliability: 100%
  34. Changeover: none
  35. Observed Inventory
  36. 1200 pieces of LH
  37. 640 pieces of RH
  38. Assembly Work Station II
  39. Dedicated to this line
  40. Manual process with one operator
  41. Cycle time: 40 seconds
  42. Reliability: 100%
  43. Changeover: none
  44. Observed F/G Inventory in warehouse
  45. 2700 pieces of LH
  46. 1440 pieces of RH
  47. Shipping Department
  48. Removes parts from finished goods warehouse and stages them for truck shipment to customer.

Create a current VSM

  1. Separate into groups of 4
  2. Have each group draw a flow chart for the Acme Stamping Company on a piece of paper.
  3. Using post-its develop a consensus flow chart
  4. Apply data in a VSM format
  5. Convert the flowchart into a VSM using Visio

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