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Copyright Manos/Alukal 2002
Fun Current State Icons
?
?
?
Fax
o
&@#$%!
Traditional Manufacturer
Supplier Customer
information Information Flow Area information
Start with
Customer
Information
first
Daily
Daily
Daily
Daily
Daily
Daily
Weekly Daily
Weekly Daily
Weekly Daily
Process
Flow
Weekly Daily
Weekly Daily
Stamping
Weekly Daily
Stamping
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
C/T=1 sec
Weekly Daily
C/T=1 sec
C/O= 4 hrs
Weekly Daily
C/T=1 sec
C/O= 4 hrs
Rel.= 98%
Weekly Daily
C/T=1 sec
C/O= 4 hrs
Rel.= 98%
FPY = 95%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
C/T=1 sec
C/O= 4 hrs
Rel.= 98%
FPY = 95%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
=1
C/T=1 sec
C/O= 4 hrs
Rel.= 98%
FPY = 95%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
=1
C/T=1 sec
C/O= 4 hrs
Rel.= 98%
FPY = 95%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
=1
C/T=1 sec
C/O= 4 hrs
Rel.= 98%
FPY = 95%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
=1
C/T=1 sec C/T=
C/O= 4 hrs C/O=
Rel.= 98% Rel.=
FPY = 95% FPY =
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
=1
C/T=1 sec C/T=39 sec
C/O= 4 hrs C/O= 11 min
Rel.= 98% Rel.= 99%
FPY = 95% FPY = 90%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
=1 =1
C/T=1 sec C/T=39 sec
C/O= 4 hrs C/O= 11 min
Rel.= 98% Rel.= 99%
FPY = 95% FPY = 90%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
=1 =1 =1
C/T=1 sec C/T=39 sec C/T=17 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min
Rel.= 98% Rel.= 99% Rel.= 80%
FPY = 95% FPY = 90% FPY = 100%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
=1 =1 =1 =2
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
Copyright Manos/Alukal 2002
Current State Map
Dewey,
Phlye- Cheatem &
Biknight Howe
5,300 pcs/mo.
265 pcs/day
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Weekly Daily
Introduction
History of Lean
8 Wastes of Lean
Lean Building Blocks
OMIT What U DO
Overproduction
Motion
Inventory
Transportation
Waiting
Underutilized People
Defects
Over-processing
Copyright Manos/Alukal 2002
Overproduction
Makingmore-earlier-faster than
the next process needs it.
Just in case logic
Unbalanced workload
Unleveled scheduling
5S Workplace
Organization and
Standardization
A place for everything and
everything in its place
After
Before
Visual
Signs, lines, labels and color coding
Andon Lights
Display Panels
Range
Markings
On Gauges
Shadow Boards
Copyright Manos/Alukal 2002
124 W. Polk Street, Suite 101
Chicago, Illinois 60605-2770
Tel 312-294-9900 Fax 312-294-9911
www.proferoinc.com
Standard Work
Reduce task variability
Productivity
Productivity
Layout
Streamlined Layout
A B C
Tracked 4 People
for 30 Minutes
Machining
Support
Traditional Lean
Factory Capacity 125,000 120,000
Factory Size (Sq ft) 500,000
Copyright Manos/Alukal 2002
170,000
124 W. Polk Street, Suite 101
Chicago, Illinois 60605-2770
Tel 312-294-9900 Fax 312-294-9911
www.proferoinc.com
Point-of-Use-Storage
Keep it where you use it
in the vicinity
Monthly
Step 1 2 3
+ + Total 30 min
Fastest 21 min
10 min 10 min 10 min
Batch Size = 10
Step 1 2 3
+ + Total 30 min
Fastest 21 min
10 min 10 min 10 min
Batch Size = 10
+ + Total 12 min
Fastest 3 min
1 min 1 min 1 min
Batch Size = 1 Copyright Manos/Alukal 2002
Information on Batch Size
Reduction
The best batch size is one piece flow, or
make one and move one!
If one piece flow is not appropriate, reduce
the batch sizes to the smallest size possible
In some cases, one-piece might be one tray
or pallet or container of parts
Affected by quick changeover and workplace
layout
Responsive to demand, makes the
organization more flexible
Copyright Manos/Alukal 2002
Batch Versus Flow
Make-one, Move-one
Quick Changeover
Changeovers in less than ten
minutes
9
8
7
6
5
4
3 A B C D E
2
1
0
Monday Tuesday Wednesday Thursday Friday
1 hour C/O
9
8
7
6 B D A C E
5
4
3
2
1
A C E B D
0
Monday Tuesday Wednesday Thursday Friday
9 E
8 C
E B
7 B
6 D
5 B
D A
4
A
3
2 C
A C E
1 E
0
Monday Tuesday Wednesday Thursday Friday
Autonomation
Self Inspection
Poka-yoke
You cannot pass a bad part on to
the next operation
Total Productive
Maintenance
Have the equipment available
when you need it
C/T = 30s
Process 6
Process 11 Process 10 Process 9 Process 8 Process 7
Out
C/T = 30s C/T = 30s Copyright
C/T = 60s 2002 C/T = 30s
Manos/Alukal C/T = 30s
Demand Change Example
Time Available = 27,000 sec
Demand = 450 units
Takt Time = 60 sec
Process 1 Process 2 Process 3 Process 4 Process 5
In C/T = 45s C/T = 45s C/T = 15s C/T = 15s C/T = 30s
C/T = 30s
Process 6
Process 11 Process 10 Process 9 Process 8 Process 7
Out
C/T = 30s C/T = 30s Copyright
C/T = 60s 2002 C/T = 30s
Manos/Alukal C/T = 30s
124 W. Polk Street, Suite 101
Chicago, Illinois 60605-2770
Tel 312-294-9900 Fax 312-294-9911
www.proferoinc.com
Pull System
Replenish at the Demand of the
Customer
Order Quantity
=2
Process B Process A
In this example,
Process A can produce Order Point
faster than what =4
Process B needs. Copyright Manos/Alukal 2002
6 Kanban Rules
Continuous
Improvement
Continuous Improvement (C. I. or
Kaizen, in Japanese), is an essential
and never ending process
Employee suggestions
Corrective & Preventive actions
Non-conformities, defects
Customer complaints, returns
Benchmarks
The Lean wastes
Variations from the standard
Assessments, audits & competitive analyses
Research & Development activities
Copyright Manos/Alukal 2002
Continuous Improvement &
Continuous Learning
Management should have training given to
employees in Lean and quality tools, problem
solving and root cause analysis, the process
model, concepts of Theory of Constraints,
basic statistical techniques, graphical tools,
etc.
Understanding of Plan-Do-Check-Act and
Standardize-Do-Check-Act (SDCA) will be
beneficial
Copyright Manos/Alukal 2002
124 W. Polk Street, Suite 101
Chicago, Illinois 60605-2770
Tel 312-294-9900 Fax 312-294-9911
www.proferoinc.com
Kaizen Blitz
Breakthrough Strategies for
Lasting Results
KAI + ZEN
Change For the better
KAIZEN
Continuous Improvement
BLITZ
Flash or Lightning
Kaizen Blitz is Service Marked by AME (Association for Manufacturing Excellence)
Copyright Manos/Alukal 2002
What is Kaizen Blitz?
Kaizen Blitz is a combination of the Japanese
word Kaizen for continuous improvement
and the German word Blitz for lightning
It is a focused, typically week long project
where a cross-functional team reviews a
process, identifies and eliminates waste,
thereby achieving dramatic & tangible BREAK-
THROUGH (rather than incremental)
improvement results
Also called, Rapid Kaizen, Kaizen Event, etc.
Copyright Manos/Alukal 2002
What is Kaizen Blitz?
Formula
Time Available
Takt Time =
Demand
C =8 A B C D D
D =7 A B C D D
A =6 B B B B A
B =4 C C C C C
C =8 C D C C D
D =7 D D D D D
Respond quickly
Element Timeframe
Pack-out quantity Takt Seconds
Paced withdrawal Pitch Minutes
Material Handler Shift Hours
time frame or milk run Customer Days
Copyright Manos/Alukal 2002
8. What process improvements
need to be made?
Look at the Future State Map and
determine where improvements have
to be made from the Current State to
get there
These become the projects to work on
They can be performed in Kaizen Blitz
mode or as a longer project based on
need
C/0 = 4 hours
Copyright Manos/Alukal 2002
What to look for
I
the product.
Shared
I I I
2 Weeks =1 5,425 =1 1,400 =1 1,225 =2
Build
C/T=1 to
sec a Supermarket
C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q2. Build to Shipping or Build
Phlye-
Forecast
MRP MRP
to a Supermarket?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
A. Our customers require delivery
Daily in less time
ofStamping
our ordering raw
Spot Weld materials and making
Deburr Assemble
I
the product.
Shared
I I I
2 Weeks =1 5,425 =1 1,400 =1 1,225 =2
Build
C/T=1 to
sec a Supermarket
C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q.3 Where can we flow?
Phlye-
Forecast
MRP MRP
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
I I =4
2 Weeks =1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Eliminates inventory and multiple schedules
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
I I =4
2 Weeks =1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
I I =4
2 Weeks =1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q4. Where do we use a Supermarket
Phlye-
Forecast
MRP
MRP
Pull System?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
I I =4
2 Weeks =1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q4. Where do we use a Supermarket
Phlye-
Forecast
MRP
MRP
Pull System?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Raw materialsWeekly P/T = 20 min 265 pcs/day
SW/Deburr/Assemble
Stamping
Shared
I I =4
2 Weeks =1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q4. Where do we use a Supermarket
Phlye-
Forecast
MRP
MRP
Pull System?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Shared Weekly
resources P/T = 20 min 265 pcs/day
SW/Deburr/Assemble
Stamping
Shared
I I =4
2 Weeks =1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q4. Where do we use a Supermarket
Phlye-
Forecast
MRP
MRP
Pull System?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
I I =4
2 Weeks =1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q4. Where do we use a Supermarket
Phlye-
Forecast
MRP
MRP
Pull System?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q4. Where do we use a Supermarket
Phlye-
Forecast
MRP
MRP
Pull System?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q5. Where do we trigger production?
Phlye-
Forecast
MRP
MRP
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q5. Where do we trigger production?
Phlye-
Forecast
MRP
MRP
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly
Weekly Schedule Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q6. How do we Level the production
Phlye-
Forecast
MRP
MRP
mix?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q6. How do we Level the production
Phlye-
Forecast
MRP
MRP
mix?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q6. How do we Level the production
Phlye-
Forecast
MRP
MRP
mix?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly Daily
Daily
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q6. How do we Level the production
Phlye-
Forecast
MRP
MRP
mix?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
Weekly Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q6. How do we Level the production
Phlye-
Forecast
MRP
MRP
mix?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q7. What increment of work
Phlye-
Forecast
MRP
MRP
will we release?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Q7. What increment of work
Phlye-
Forecast
MRP
MRP
will we release?
Monthly Dewey,
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
P/T = 20 min 265 pcs/day
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
C/O= 4 hrs C/O= 11 min C/O= 0 min C/O= 5 min
C/T =
Rel.= 98% Rel.= 99% Rel.= 80% Rel.= 100%
104 sec
FPY = 95% FPY = 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30/60/90 Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Weekly Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Lets
Phlye-
recalculate the Cycle Time
Forecast
MRP MRP
and Lead Time
Monthly Dewey,
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
10 days 20.5 days 5 days
Copyright Manos/Alukal 2002 4.5 days 40 days
1 sec 39 sec 17 sec 48 sec 105 sec
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Lets
Phlye-
recalculate the Cycle Time
Forecast
MRP MRP
and Lead Time
Monthly Dewey,
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
Copyright Manos/Alukal 2002
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Lets
Phlye-
recalculate the Cycle Time
Forecast
MRP MRP
and Lead Time
Monthly Dewey,
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
As an estimate, how much
Scheduling
P/T = 20 min 265 pcs/day
inventory do
Weekly we want to keep Daily
OXOX in OXOX
Daily
the Supermarkets?
SW/Deburr/Assemble
Stamping
Shared
=4
=1
C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
Copyright Manos/Alukal 2002
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Lets
Phlye-
recalculate the Cycle Time
Forecast
MRP MRP
and Lead Time
Monthly Dewey,
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
As an estimate, how muchScheduling
P/T = 20 min 265 pcs/day
inventory do
Weekly we want to keep Daily
OXOX in OXOX
Daily
the Supermarkets?
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
Copyright Manos/Alukal 2002
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Lets
Phlye-
recalculate the Cycle Time
Forecast
MRP MRP
and Lead Time
Monthly Dewey,
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Lets
Phlye-
recalculate the Cycle Time
Forecast
MRP MRP
and Lead Time
Monthly Dewey,
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days
1 sec 90 sec
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Lets
Phlye-
recalculate the Cycle Time
Forecast
MRP MRP
and Lead Time
Monthly Dewey,
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
2 days
20 min
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Lets look at support area improvements
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Lean is not just for the
shop floor
How can we apply this to other areas?
Requires creativity
SW/Deburr/Assemble
Stamping
Lets look at support area improvements
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
2 days
20 min
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Lets look at support area improvements
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
2 days
20 min
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Lets look at support area improvements
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
1 hour
20 min
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
1 hour
20 min
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Measurable Improvement
Lead-time 40 days 7 days
Cycle time 105 sec 91 sec
Inventory 10,700 pcs 1,855 pcs
Kaizen events
Stamping changeover time
Deburring reliability
Spot weld quality
Other benefits
Operators in cell cross-trained
More flexibility
Reduced lead-time and defects = happier customers
Copyright Manos/Alukal 2002
What to look for
Make it manageable
Not too may
Not too few
Look for logical breaks
Thumb rule
Probably somewhere between 3-7 loops
Remember the point is to make it
easier for implementation
Copyright Manos/Alukal 2002
Future State Map
1 hour
20 min
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
1 hour
20 min
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Start with the Pacemaker Loop
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
1 hour
20 min Loop 1
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
1 hour
Loop 2 20 min Loop 1
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
Future State Map
1 hour
Loop 2 20 min Loop 1
L/T = 2 days
30 day Prod Ctrl Order Entry
Forecast Monthly Dewey,
Phlye- MRP MRP
Daily Cheatem &
Biknight L/T= 2 days Howe
Weekly 5,300 pcs/mo.
Scheduling 265 pcs/day
P/T = 20 min
Weekly OXOX Daily
Daily OXOX
SW/Deburr/Assemble
Stamping
Shared
=4
=1
2 days
3 days C/T=1 sec C/T=39 sec 2 days
Loop 3 C/T=17 sec C/T=48 sec
Stamping
C/O=
C/O =44 hrs
hrs C/O= 11 min C/O= 0 min C/O= 5 min
Deburr C/T =
Rel.= 98% Rel.= 99% Rel.=
Rel. 80%
= 80% Rel.= 100%
104 sec
SW FPY
FPY = 95% FPY = 90%
= 90% FPY = 100% FPY = 98%
3 days 2 days Copyright Manos/Alukal 2002 2 days 7 days
1 sec 90 sec 91 sec
The Plan
Project
Subproject
Tasks
2 STAMPING 1 DAY
PULL INVENTORY
STAMPING BATCH SIZE
C/O
Communication Board
VSM Manager Value Stream Board
VSM Team Current Future Team
VSM Current State
VSM Future State Plan Review Notes
Value Stream Plan
Value Stream Review
Hold brief meetings at the VSM Board
Copyright Manos/Alukal 2002
Role of the Review
Continuous
Current State Future State Improvement
The eraser is
your best friend!
Copyright Manos/Alukal 2002
Questions?
Wrap-up
Evaluations
Thank you