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8 stepfuturestatevaluestreammapping
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Transcript of 8 stepfuturestatevaluestreammapping
![Page 1: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/1.jpg)
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
![Page 2: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/2.jpg)
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
![Page 3: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/3.jpg)
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
![Page 4: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/4.jpg)
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
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![Page 5: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/5.jpg)
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
![Page 6: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/6.jpg)
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
![Page 7: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/7.jpg)
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
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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
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![Page 9: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/9.jpg)
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
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![Page 10: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/10.jpg)
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
![Page 11: 8 stepfuturestatevaluestreammapping](https://reader031.fdocuments.us/reader031/viewer/2022011721/58a25c381a28abb92b8b4b4f/html5/thumbnails/11.jpg)
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
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