Step 0: Current State

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 50%CT = 10 s

PT = 10 s CT = 8 s

PT = 8 s

C/O = 5minCT = 4 s

PT = 4 s

Y = 80%CT = 9 s

PT = 9 s

135.000 27.000 27.000 27.000 27.000 27.000 54.000 6 10 9 4 4 9

WT

PT

1 11 1

Demand per day: 2500 MOQ =10Available time per day: 7,5 hoursTakt = 10,8 seconds

I I I I

Assembly2

CT = 4 s

PT = 4 s

Y = 80%

1

2500 pcs

I

5000 pcs

I

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

2500 pcs 2500 pcs 2500 pcs 2500 pcs max 12.500 pcs

www.panview.nl

Step 1:Can all Workstations Keep Takt?

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 50%CT = 10 s

PT = 10 s CT = 4 s

PT = 4 s

Y = 80%CT = 9 s

PT = 9 s

1 11 1

Takt = 10,8sPCT = 10sMOQ =10

I I I I

Assembly2

CT = 4 s

PT = 4 s

Y = 80%

1

2500 pcs

I

5000 pcs

I

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

2500 pcs 2500 pcs 2500 pcs 2500 pcs

A ≥60%Or CT ≤5s

max 12.500 pcs

CT = 8 s

PT = 8 s

C/O = 5min

www.panview.nl

Step 2: Finished Goods Strategy?

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 60%CT = 10 s

PT = 10 s CT = 4 s

PT = 4 s

Y = 80%CT = 9 s

PT = 9 s

1 11 1

Takt = 10,8sPCT = 10s

I I I I

Assembly2

CT = 4 s

PT = 4 s

Y = 80%

1

2500 pcs

I

5000 pcs

I

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

2500 pcs 2500 pcs 2500 pcs 2500 pcs

Direct Shipping

max 12.500 pcs

CT = 8 s

PT = 8 s

C/O = 5min

www.panview.nl

Step 3: Where can we implement Flow?

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 60%CT = 10 s

PT = 10 s CT = 4 s

PT = 4 s

Y = 80%CT = 9 s

PT = 9 s

1 11 1

Takt = 10,8sPCT = 10s

I I I I

Assembly2

CT = 4 s

PT = 4 s

Y = 80%

1

2500 pcs

I

5000 pcs

I

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

2500 pcs 2500 pcs 2500 pcs 2500 pcs

Implement Flow

F I F OMax. 2500

Yield ≥ 90%

max 12.500 pcs

CT = 8 s

PT = 8 s

C/O = 5min

www.panview.nl

Step 4: Where do we need to buffer Flow?

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 60%CT = 10 s

PT = 10 s CT = 4 s

PT = 4 s

Y = 80%CT = 9 s

PT = 9 s

1 11 1

Takt = 10,8sPCT = 10s

I I I

Assembly2

CT = 4 s

PT = 4 s

Y = 80%

1

2500 pcs

I

5000 pcs

I

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

2500 pcs 2500 pcs 2500 pcsF I F O

Max. 2500

Assembly 1+2U

1

A = 90%

CT = 8 s

PT = 8 s

Implement FIFO

Implement FIFO

max 12.500 pcs

CT = 8 s

PT = 8 s

C/O = 5min

www.panview.nl

Step 5: How do we control production?

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 60%CT = 10 s

PT = 10 s CT = 9 s

PT = 9 s

1 11 1

Takt = 10,8sPCT = 10s

I I

Assembly2

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

2500 pcs 2500 pcsF I F O

Max. 2500

Assembly 1+2U

1

A = 90%

CT = 8 s

PT = 8 s

Implement Supermarket

F I F OMax. 2500

F I F OMax. 2500

Implement Supermarket

max 12.500 pcs

CT = 8 s

PT = 8 s

C/O = 5min

www.panview.nl

Step 6: Where is the pacemaker?

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 60%CT = 10 s

PT = 10 s CT = 9 s

PT = 9 s

1 11 1

Takt = 10,8sPCT = 10s

Assembly2

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

F I F OMax. 2500

Assembly 1+2U

1

A = 90%

CT = 8 s

PT = 8 s

F I F O

Max. 333

F I F OMax. 333

max 12.500 pcs

Max. 2500 Max. 333

One signal neccessary

CT = 8 s

PT = 8 s

C/O = 5min

www.panview.nl

Step 7: How do we level the mix?

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 60%CT = 10 s

PT = 10 s CT = 9 s

PT = 9 s

1 11 1

Takt = 10,8sPCT = 10s

Assembly2

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

F I F OMax. 2500

Assembly 1+2U

1

A = 90%

CT = 8 s

PT = 8 s

F I F O

Max. 333

F I F OMax. 333

max 12.500 pcs

Max. 2500

per color Max. 333

Level the mix at the pacemaker

(color)

CT = 8 s

PT = 8 s

C/O = 5min

www.panview.nl

Step 8: Wat size increments should we feed the line?

Gasfilling

Assembly1

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 60%CT = 10 s

PT = 10 s CT = 9 s

PT = 9 s

1 11 1

Takt = 10,8sPCT = 10s

Assembly2

Waiting time: 324.000 sec = 12 daysProcess Time: 42 secProduction Lead time 324.050 sec = 12.0003 days

Production Control

F I F OMax. 2500

Assembly 1+2U

1

A = 90%

CT = 8 s

PT = 8 s

F I F O

Max. 333

F I F OMax. 333

max 12.500 pcs

Max. 333

per color Max. 333

Intervall = 20 min

O X O X

CT = 8 s

PT = 8 s

C/O = 5minEPEI = 7.5 h

www.panview.nl

Future State (incl Timeline)

Gasfilling

Painting

Molding

Logo

Printing

Supplier Customer

CT = 6 s

PT = 6 s

A = 60%CT = 10 s

PT = 10 s CT = 8 s

PT = 8 s

CT = 9 s

PT = 9 s

135.000 3.600 3.600 1.800 1.800 27.000 6 10 8 8 9

WT

PT

11 1

Takt = 10,8sPCT = 10s

Current State Future StateWaiting time: 324.000 sec = 12 days 148.500 sec = 5,5 daysProcess Time: 41 sec 41 secProduction Lead time 324.049 sec = 12.0003 days 148.541 sec = 5.5003 days

Production Control

F I F OMax. 2500

Assembly 1+2U

1

A = 90%

CT = 8 s

PT = 8 s

F I F O

Max. 333

F I F OMax. 333

max 12.500 pcs

Max. 333

EPEI = 7.5 h

O X O X

Max. 333

per color

C/O = 5 min

www.panview.nl

Guidelines for developing future state VSM1. Is the Process Capable of meeting Customer needs?

Produce to TAKT time2. Should we produce to Supermarket or direct to Shipping?

Decide build strategy3. Where is continuous flow possible?

Create continuous flow4. Where do we need to buffer flow?

Use FIFO to buffer flow and keep sequence5. How do we control production?

Use supermarkets to control production6. Where is the pacemaker process?

Send customer schedule to one point in the process7. How do we level the production mix?

Level the production mix at the pacemaker 8. What increment of monitor / control the process?

Release small, consistent increments of work at pacemaker

www.panview.nl