1. Value Stream Mapping
- An example of Lean Tools -
Value Stream Map Supplier XYZ
" CURRENT STATE"
Standard Product Family
( 75% of Product) Production
Control
2/15/2000
FORECAST
Issues Daily Priorities
Purchase Orders Applied
Placed as needed based upon: Materials
* Gross inventory check for
spot buys
Suppliers * Bus-Route(contract) forecast
- Trident
- Reliant
- Metal West
- Others
Daily
OSP
As Ordered Plating OSP
I
Manufacturing Orders
2 -5 Da ys 2 Primary & 2
Shop Schedule
Secondary Suppliers
Dallas
2X Month
Inspection
3X Week
M,W,F 1
I
2 D ays
95% First Pass Yield
Inspection
Sheer Turret Deburr Brakes Assy & Paint Ship / FGI
I I I I I Hardware I I Packaging
1 3 11 7 6 6 7
30 Da ys Paint
5 Da ys 1 4+ D ay s 2 D a ys 14 D ays 1 Day
Ra w Stoc k .5 Da ys C /T = 1 Da y
Day Shift Only Shifts: 2 + Weekend Shifts: 2 + Weekend Shifts: 2 + Weekend Hardware: 1 Shift Operation
2 shifts / 3 people Cle an
Capacity at Turret 1 Person can operate C/T = 12 0 M in Setup: 10-120 Min Dedicated to Bus
determines when to 2 machines Assembly: 3 -5 D ays
1 shifts / 3 people Route from 5:30am to
Sheer 40-50% Productivity
Hi-Flex Capability KAIZEN Noon
C /T = 3 0 Min 98-99% Yield (buffers C /T = 6 0 Min Im plem e nt Ph os pha te
40-50% Productivity
KAIZEN used to make up for D ip C le an System
No Productivity
Measure
Deburr is a scrap)
C/O = 45-60 Min C /T = 1 D a y
Bottleneck Uptime is High - PM's
Capacity: 1 job/hr scheduled on W/E KAIZEN
(~10 planks/job) KAIZEN In cre a se Ca pa city X3 a t KAIZEN
C /T = 1 05 Min Se tup R e duc tions C /T = 12 0 Min
paint booth, pow de r D e dica te d Staging
pa in t, an d batch ove n Are a s
Production Lead
Time
30 Days 5 Days 14 Days 2 Days 14 Days 5 Days 2 Days 72 Days
Processing Time
30 min 105 min 120 min 120 min 60 min 1 day 1 day
2days7hrs25min

2. Value Stream Mapping
- An example of Lean Tools -
Value Stream Map Supplier XYZ
" FUTURE STATE"
Standard Product Family
( 75% of Product) Production
Control
2/25/2000
FORECAST
Issues Daily Priorities
Purchase Orders Daily Orders - EDI Pull Applied
Orders are launched at Materials
calculated re-order points for
Raw Good Kanbans Daily Pull Orders
Suppliers
- Trident
- Reliant
- Metal West
- Others
Daily
Manufacturing Orders OSP OSP
Plating
Based on Finished Goods
Replenishment Triggers & I
Spot Buy Orders
2-5 D ays 2 Primary & 2
Shop Schedule Secondary Suppliers
As Ordered
k
oc
St
w
Ra
3X / Week Dallas
Inspection
3X Week
M,W,F 1
Sho p ord ers ar e Lo ad Le ve led b as ed
on Pr oduc t F am ily Sch edu lin g Ru le s 95% First Pass Yield
Inspection
Sheer Turret Deburr Brakes Assy & Paint Ship /
Hardware Packaging
? ?? D ay s
1
Day Shift Only .5 Da ys
3
Shifts: 2 + Weekend .5 D ay s
11
Shifts: 2 + Weekend
.5 D ay s
7
Shifts: 2 + Weekend
.5 Da ys
6
Hardware:
2 shifts / 3 people .5 D a ys
6
C /T = 1 D ay
.5 D ay s
7
1 Shift Operation
Capacity at Turret 1 Person can operate C /T = 1 20 Min Setup: 10-120 Min Dedicated to Bus
30 D a ys Assembly:
determines when to 2 machines Route from 5:30am to Finished Goods
?
Ra w Stoc k 40-50% Productivity 1 shifts / 3 people
Sheer
Hi-Flex Capability
C /T = 6 0 M in
Noon Inventory
C /T = 3 0 Min 98-99% Yield (buffers
No Productivity
40-50% Productivity used to make up for Orders are launched at
Measure
scrap)
Inventory Sizing of Dallas provided gas C /T = 1 Da y
calculated re-order points for
C/O = 45-60 Min
Uptime is High - PM's panel enclosures & gas panel piece Finished Good Kanbans
Capacity: 1 job/hr scheduled on W/E parts (gas panel parts & spares )
(~10 planks/job)
C /T = 1 05 Min C/T = 12 0 M in
Production Lead
Time
30 Days .5 Days .5 Days .5 Days .5 Days .5 Days .5 Days 33 Days
Processing Time
30 min 105 min 120 min 120 min 60 min 1 day 1 day
2days7hrs25min