VSM AND WIP WITH RELATED TO ARENA

SIMULATION SOFTWARE

BY Md. Asrafuzzaman

IPE, SUST

Objectives

Improve shop floor efficiency and productivity by examining the existing WIP scenario and reducing WIP in the current manufacturing line.

Background We find that in our production floor WIP is

a big problem and root cause of many other problems.

These problems are:• Maintaining 5S, • Quality issues, • On time delivery, • Line Efficiency, • Learning curves, • Line layout setup time

Status of one day of Manufacturing flow

Like at statistics at 16-6-2015• Total cut pieces at = 34602 pieces

WIP= 8564 pieces• Total input in line at =26038 Pieces

WIP= 103 pieces• Total output line at = 25935 pieces

WIP= 492 pieces• Total good pass quantity to finishing at

=25443 pieces

Some pictures of WIP in our production floor

Some picture related to 5S

Steps of the study First step: VSM a lean tool for

visualizing the real scenario of the manufacturing flow

Second step: Identify the WIP and find the way of eliminating WIP

Third step: Simulate the present situation and proposed improvement by using Arena simulation software

VSM

A value stream involves all the steps, both value added and non value added, required to complete a product or service from beginning to end

Overall steps involved in the study

VALUE STREAM & IDENTIFYING WIP

VALUE STREAM

RELAXATION

CUTTING SEWING FINISHING

PROCESS

PROCESS

PROCESS

PROCESS

RAW MATERIALS

FINISHED PRODUCT

CUSTOMER

WIP WIP WIP

THE STEPS - VALUE STREAMS MAPPING

Product Family

Current State

drawing

Future State drawing

Plan & Implementatio

n

Understanding how the shop floor currently operates. The foundation for the value state.

Designing Lean Flow

Current state

Improved scenario of VSM

Measurable Metrics & Performance

Metric Current Estimate

Target from Future State Map

Process Time 55.26 Min. 55.26 Min.

Lead Time 8.390 Days 3.14 Days

First Time Quality 80% 80%

Data analysis and findings

The data and information was collected through the observation of the production floor and some past record from the industrial engineering and planning department .

Finally all data has been analyzed by using various types of tables, some tools such as cause effect diagram and 5S.

Causes of WIP Operator absenteeism Machine breakdown Improper line balancing in the

beginning of the layout. Raw materials supply problem Quality issues

Improvement proposal Operator skill matrix operation base Implementation of TPM ( Total

Productive Maintenance) Sewing line Layout analysis and

layout proposal Building supplier relationship, its a

long term process and cost and quality related issues.

Our IE and Quality team is working on this, we will work on this issue in future.

Operators skill matrixq

Implementation of TPM1. There are 8

pillars of TPM2. Already we are

practising some of the pillars

3. Another 1. Autonomous

maintenance2. Quality

maintenance3. Planned

maintenancewe can implement

Simulation analysis of Layout By using arena 1. present situation layout 2. proposed layout result.

Present line in the Arena Simulation

Simulating result

PDF Document

Showing WIP by Arena

Cost related to implementation of TPM

To implementation TPM need 3 or 4 man for every unit, but they have to work extra time or holyday when production will not running. So have to pay for extra time duty of the employee.

Total man power need = 12 to 16• Already we have 13 man for

maintenance purpose

Cost related to Buy the Software

I have no exact purchase related idea.

Hear provided contact details of selling partner of Arena ( RockWell Automation)

Selling partnerChinaBeijing EnSkyContact Name: Zhang QingPhone: +86-10-59009377Email: info@ensky.com.cnWebsite: www.ensky.com.cn

https://www.arenasimulation.com/purchasing-options/global-partners-contact-for-sales

Benefits Improve efficiency and productivity On time delivery Improve 5S Reduce new style layout time

Benefits

Our floor space rent per sq. Ft per month 15.07 Taka, so that if we reduce WIP then our every sq. Ft of space will be effectively used

Total CPM is 0.08$ so that if normal Layout time is 8 hour more than normal layout time ( 6 hour ) then extra loss of taka per month, 19353.6 $ ( extra cost for 1 lay out 537.6 $)

Benefits If we miss the shipment schedule then we

have to pay for air shipment, which manufacturer have to pay for lost the shipment schedule.

Cost per kg for Europe: 3$ and 1.6$ for non Europe air shipment.

So per container 400 cartoon cost:• Europe : 24000$ ( per container)• Non Europe: 12800$

Simulation software related

For improving the running low efficient line performance usually do:• Layout change• More skill and efficient operator involve• Process improvementTo do these we need around 3 hours to come out

expected results.If the result will not come then we will loss for

4867.2$ for one month ( on basis of line status of 26-5-2015, 13 line of that day ware not meet the expected result)

Microsoft Office Excel Worksheet

Case study result provided by RockWell Automation

Challenges: Increase throughput Decrease inventory Decrease operating

expenses and cycle time

Do a better job of capacity planning

Gain access to accurate, timely information

Results after using Arena: The model helped the

manufacturer increase sales by more than $1 million

The simulation effort identified several options to optimize process performance

Cycle time was reduced from 5 weeks to 3 days

Overtime and operating expenses were lowered

On-time shipping performance increased 70% to 95%

Sources: https://www.arenasimulation.com/resources/Production_simulation.pdf

Recommendation Technique such as zero defects, setup time

reduction, and Poka-Yoke can be applied. Arrange schedule training operator To reduce absenteeism and to build up

moral and trust:• Job enrichment, • Relationship improvement between employee

and management, • Worker motivation.

WIP running status and proposal

Unit Line Style Name Target Input/Day Total Input Total Output WIP C urrent WIP Target Our WIP target

Reduce pcs Reduce %

UNA

SAA Maja Crochet 1040 40165 37542 -2623 1560 1040 -520 35%

SAB Vincent Top 1150 9383 6223 -3160 1725 1150 -575 35%

SAC Vincent Top 1150 4517 1626 -2891 1725 1150 -575 35%

SAD Vincent Top 1150 7583 3916 -3667 1725 1150 -575 35%

SAE Majken dress-CWG 900 28054 25456 -2598 1620 900 -720 35%

SAF Vincent Top 1150 6504 4829 -1675 1725 1150 -575 35%

UNB

SBA Majken dress-CWG 900 20113 18218 -1895 1620 900 -720 35%

SBB Chung Top 1550 32449 30189 -2260 2325 1550 -775 35%

SBC Vincent Top 1150 6468 3731 -2737 1725 1150 -575 35%

SBD Vincent Top 1150 9269 6710 -2559 1725 1150 -575 35%

SBE Chilli tunic 690 5882 4496 -1386 1035 690 -345 35%

SBF Vincent Top 1150 9214 6651 -2563 1725 1150 -575 35%

UNC

SCA Vincent Top 1150 11438 7765 -3673 1725 1150 -575 35%

SCB Vincent Top 1150 11920 10605 -1315 1725 1150 -575 35%

SCC Chilli tunic 690 4885 3224 -1661 1035 690 -345 35%

SCD Majken dress CWH 900 9213 7319 -1894 1620 900 -720 35%

SCE Vincent Top 1150 7312 3620 -3692 1725 1150 -575 35%

SCF Rosie S-2 1590 1480 45 -1435 2385 1590 -795 35%

UND

SDA Chung Top 1550 36133 34272 -1861 2325 1550 -775 35%

SDB Maja Crochet 1040 31066 28910 -2156 1560 1040 -520 35%

SDC Vincent Top 1150 11544 8384 -3160 1725 1150 -575 35%

SDD Majken dress CWH 900 5653 4083 -1570 1620 900 -720 35%

SDE Vincent Top 1150 9342 6970 -2372 1725 1150 -575 35%

SDF Rosie S-2 1590 10698 9417 -1281 2385 1590 -795 35%

G.Total 27140 330285 274201 -56084 41790 27140 -14650 35%

Recommendation Con’t... Improve supplier relationship to get

the raw materials on time and standard quality.

Arrange the Arena Simulation commercial version software to save the dollar in relation with the interruption of the line due to experiment for process improvement

Conclusion VSM was implemented to find out the

amount of wastes and WIP in cutting, sewing and finishing section; because the selected product had a long lead time and was unable to meet the expected production rate . Cause effect and was done to identify the reason of WIP, and proposing different solution.

Conclusion Con’t... As VSM can be drawn in relatively short time with

almost no expenditure of money and as it can identify wastes with good accuracy, thus it’s very helpful for managers who are having difficulties with their low production rate, higher lead time and high production costs high WIP.

The simulation software helps to represent the real problems and analyse the total process and make scope to improve without interruption the production process, and after getting appropriate solution direct implement it in the manufacturing process.