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Value Stream Mapping PDF
Value Stream Mapping PDF
Peter L. King
Lean Dynamics, LLC
January 2010
AGENDA
Frequency 12 Trucks/Day
SHEET CALENDARING WRAPPING Lot Size 648K Sq Ft
SLITTING CHOPPING
FORMING BONDING PACKAGING
6
(3) 5
(3) 5
Transp time 3 Days
(4) (4) LABELING 4
3 M 42 Days
16 Days 12.6 Days 21 Days 7 Days NVA Time = 99 Days
15 Min 17 Min 10 Min 10 Min 8 Min VA Time = 73 Min
CUSTOMER
CAPACITY FORECAST SERVICE
(MONTHLY) REPS ORDERS
MASTER PRODUCTION
RAW MATERIAL SCHEDULE (MONTHLY)
ORDERS (MONTHLY)
Frequency 12 Trucks/Day
SHEET CALENDARING WRAPPING Lot Size 648K Sq Ft
SLITTING CHOPPING
3 M 42 Days
16 Days 12.6 Days 21 Days 7 Days NVA Time = 99 Days
15 Min 17 Min 10 Min 10 Min 8 Min VA Time = 73 Min
AGGREGATED
DEMAND
DEMAND
(MONTHLY)
SALES & MANAGEMENT CUSTOMER FORECASTS
OPERATIONS PROCESS (QUARTERLY)
PLANNING
CUSTOMER
CAPACITY FORECAST SERVICE
(MONTHLY) REPS ORDERS
MASTER PRODUCTION
RAW MATERIAL SCHEDULE (MONTHLY)
ORDERS (MONTHLY)
Frequency 12 Trucks/Day
SHEET CALENDARING WRAPPING Lot Size 648K Sq Ft
SLITTING CHOPPING
FORMING BONDING PACKAGING
6
(3) 5
(3) 5
Transp time 3 Days
(4) (4) 6 LABELING 4
Invtry 6.3M lbs Effective Invtry 2500 R Effective Invtry 3650 R Invtry 4000 Invtry 322M sq Ft
Capacity 11.8 8.9 Effective Effective Effective
SUPPLIER 2 Days 16 Days 12.6
Capacity
Days 21 Capacity 10.3
Days 7 Capacity 29 Capacity 200 Days 42
TAKT 9.5 TAKT 8.3
# # # TAKT 7.2 # TAKT 24 TAKT 120
Order Lead Frequency 1 Car/Day 6 (Master Rolls/Hr) 50 200 1000 # SKUs 2,000
1 Week SKUs SKUs (Master Rolls/Hr) SKUs (Bonded Rolls/Hr) SKUs (Slit Rolls/Hr)
Time (Cut Rolls/Hr)
Lot Size 140K lbs Utilization 80%
# SKUs 4 Utilization 93% Utilization 70% Utilization 83% Utilization 60%
Transp time 7 Days Lead time 15 Min Lead time 17 Min Lead time 10 Min Lead time 10 Min Lead time 8 Min
Yield 87% Yield 87% Yield 98% Yield 100% Yield 100%
Reliability 90% Reliability 98% Reliability 95% Reliability 98% Reliability 98%
UPtime 73.6% UPtime 61% UPtime 69% UPtime 98% UPtime 98%
# SKUs 50 # SKUs 200 # SKUs 1000 # SKUs 1800 # SKUs 2000
Batch size 1 roll Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll Batch size 1 Cut Roll
EPEI 9 days KEY
EPEI 13 days EPEI 7 days EPEI 7 days EPEI 7 days
C/O time 1 hr K = 1,000
C/O time 45 Min C/O time 5 Min C/O time 0 C/O time 0
C/O loss 2 Rolls M = 1,000,000
C/O loss ~0 C/O loss ~0 C/O loss 0 C/O loss 0 B = 1,000,000,000
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
3 M 42 Days
16 Days 12.6 Days 21 Days 7 Days NVA Time = 99 Days
15 Min 17 Min 10 Min 10 Min 8 Min VA Time = 73 Min
AGGREGATED
DEMAND
DEMAND
(MONTHLY)
SALES & MANAGEMENT CUSTOMER FORECASTS
CUSTOMER
CAPACITY FORECAST SERVICE
(MONTHLY) REPS ORDERS
MASTER PRODUCTION
RAW MATERIAL SCHEDULE (MONTHLY)
ORDERS (MONTHLY)
Frequency 12 Trucks/Day
SHEET CALENDARING WRAPPING Lot Size 648K Sq Ft
SLITTING CHOPPING
FORMING BONDING PACKAGING
6
(3) 5
(3) 5
Transp time 3 Days
(4) (4) 6 LABELING 4
Invtry 6.3M lbs Effective Invtry 2500 R Effective Invtry 3650 R Invtry 4000 Invtry 322M sq Ft
Capacity 11.8 8.9 Effective Effective Effective
SUPPLIER 2 Capacity 10.3 29
Material Flow
Days 16 Days 12.6 Days 21 Capacity
Days 7 Capacity Capacity 200 Days 42
TAKT 9.5 TAKT 8.3
# # # TAKT 7.2 # TAKT 24 TAKT 120
Order Lead Frequency 1 Car/Day 6 (Master Rolls/Hr) 50 200 1000 # SKUs 2,000
1 Week SKUs SKUs (Master Rolls/Hr) SKUs (Bonded Rolls/Hr) SKUs (Slit Rolls/Hr)
Time (Cut Rolls/Hr)
Lot Size 140K lbs Utilization 80%
# SKUs 4 Utilization 93% Utilization 70% Utilization 83% Utilization 60%
Transp time 7 Days Lead time 15 Min Lead time 17 Min Lead time 10 Min Lead time 10 Min Lead time 8 Min
Yield 87% Yield 87% Yield 98% Yield 100% Yield 100%
Reliability 90% Reliability 98% Reliability 95% Reliability 98% Reliability 98%
UPtime 73.6% UPtime 61% UPtime 69% UPtime 98% UPtime 98%
# SKUs 50 # SKUs 200 # SKUs 1000 # SKUs 1800 # SKUs 2000
Batch size 1 roll Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll Batch size 1 Cut Roll
EPEI
C/O time
C/O loss
9 days
1 hr
2 Rolls
EPEI
C/O time
13 days
45 Min
EPEI
C/O time
7 days
5 Min
EPEI
C/O time
7 days
0
Data boxes
EPEI
C/O time
7 days
0
KEY
K = 1,000
M = 1,000,000
C/O loss ~0 C/O loss ~0 C/O loss 0 C/O loss 0 B = 1,000,000,000
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
3 M 42 Days
16 Days 12.6 Days 21 Days 7 Days NVA Time = 99 Days
15 Min 17 Min 10 Min 10 Min 8 Min VA Time = 73 Min
Timeline
CALENDARING WRAPPING
SLITTING CHOPPING CUSTOMERS,
BONDING PACKAGING
(3) 5
(3) 5 DISTRIBUTORS
(4) 6 LABELING 4
Invtry 3650 R Invtry 4000 Invtry 322M sq Ft Quantity/time 230M Sq Ft/Mo
Eff Capac 8.9 Eff Capac 10.3 Eff Capac 29
Days 21 Days 7
Eff Capac 200 Days 42 TAKT 320K Sq Ft/Hr
TAKT 8.3 TAKT 7.2 TAKT 24
# # TAKT 120
(Master Rolls/Hr) 200 1000 # SKUs 2,000 Lead time Exp 7 Days
SKUs (Bonded Rolls/Hr) SKUs (Slit Rolls/Hr) (Cut Rolls/Hr)
Utilization 93% Utilization 70% Utilization 83% Utilization 60%
Lead time 17 Min Lead time 10 Min Lead time 10 Min Lead time 8 Min Frequency 12 Trucks/Day
Yield 87% Yield 98% Yield 100% Yield 100% Lot Size 648K Sq Ft
Reliability 98% Reliability 95% Reliability 98% Reliability 98% Transp time 3 Days
UPtime 61% UPtime 69% UPtime 98% UPtime 98%
# SKUs 200 # SKUs 1000 # SKUs 1800 # SKUs 2000
Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll Batch size 1 Cut Roll
EPEI 13 days EPEI 7 days EPEI 7 days EPEI 7 days
C/O time 45 Min C/O time 5 Min C/O time 0 C/O time 0
C/O loss ~0 C/O loss ~0 C/O loss 0 C/O loss 0
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
External External
Customer Supplier
BONDING
3 Process Inventory
Step
1.5
Inventory Managed
Number of operators
in a
1.5 assigned to a process FIFO First In – First Out
step
mode
Material to a customer
or from a supplier
Fork Truck
Conveyor
Tractor Trailer
Railcar
CALENDARING WRAPPING
SLITTING CHOPPING CUSTOMERS,
BONDING PACKAGING
(3) 5
(3) 5 DISTRIBUTORS
(4) 6 LABELING 4
Invtry 3650 R Invtry 4000 Invtry 322M sq Ft Quantity/time 230M Sq Ft/Mo
Eff Capac 8.9 Eff Capac 10.3 Eff Capac 29
Days 21 Days 7
Eff Capac 200 Days 42 TAKT 320K Sq Ft/Hr
TAKT 8.3 TAKT 7.2 TAKT 24
# # TAKT 120
(Master Rolls/Hr) 200 1000 # SKUs 2,000 Lead time Exp 7 Days
SKUs (Bonded Rolls/Hr) SKUs (Slit Rolls/Hr) (Cut Rolls/Hr)
Utilization 93% Utilization 70% Utilization 83% Utilization 60%
Lead time 17 Min Lead time 10 Min Lead time 10 Min Lead time 8 Min Frequency 12 Trucks/Day
Yield 87% Yield 98% Yield 100% Yield 100% Lot Size 648K Sq Ft
Reliability 98% Reliability 95% Reliability 98% Reliability 98% Transp time 3 Days
UPtime 61% UPtime 69% UPtime 98% UPtime 98%
# SKUs 200 # SKUs 1000 # SKUs 1800 # SKUs 2000
Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll Batch size 1 Cut Roll
EPEI 13 days EPEI 7 days EPEI 7 days EPEI 7 days
C/O time 45 Min C/O time 5 Min C/O time 0 C/O time 0
C/O loss ~0 C/O loss ~0 C/O loss 0 C/O loss 0
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
Note: Not all of these data will be relevant in every case - and others may be added
to completely describe issues relevant to specific processes .
© 2009 - LEAN DYNAMICS LLC – ALL RIGHTS RESERVED 15
INVENTORY STORAGE DATA BOX
Icons
Process boxes
CALENDARING WRAPPING
SLITTING CHOPPING CUSTOMERS,
BONDING PACKAGING
(3) 5
(3) 5 DISTRIBUTORS
(4) 6 LABELING 4
Invtry 3650 R Invtry 4000 Invtry 322M sq Ft Quantity/time 230M Sq Ft/Mo
Eff Capac 8.9 Eff Capac 10.3 Eff Capac 29
Days 21 Days 7
Eff Capac 200 Days 42 TAKT 320K Sq Ft/Hr
TAKT 8.3 TAKT 7.2 TAKT 24
# # TAKT 120
(Master Rolls/Hr) 200 1000 # SKUs 2,000 Lead time Exp 7 Days
SKUs (Bonded Rolls/Hr) SKUs (Slit Rolls/Hr) (Cut Rolls/Hr)
Utilization 93% Utilization 70% Utilization 83% Utilization 60%
Lead time 17 Min Lead time 10 Min Lead time 10 Min Lead time 8 Min Frequency 12 Trucks/Day
Yield 87% Yield 98% Yield 100% Yield 100% Lot Size 648K Sq Ft
Reliability 98% Reliability 95% Reliability 98% Reliability 98% Transp time 3 Days
UPtime 61% UPtime 69% UPtime 98% UPtime 98%
# SKUs 200 # SKUs 1000 # SKUs 1800 # SKUs 2000
Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll Batch size 1 Cut Roll
EPEI 13 days EPEI 7 days EPEI 7 days EPEI 7 days
C/O time 45 Min C/O time 5 Min C/O time 0 C/O time 0
C/O loss ~0 C/O loss ~0 C/O loss 0 C/O loss 0
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
Data boxes
The VSM should show all of the major communications which influence
production planning, forecasting, order fulfillment, and detailed
scheduling
AGGREGATED
DEMAND
DEMAND
(MONTHLY)
SALES & MANAGEMENT CUSTOMER FORECASTS
OPERATIONS PROCESS (QUARTERLY)
PLANNING
CUSTOMER
CAPACITY FORECAST SERVICE
(MONTHLY) REPS ORDERS
MASTER PRODUCTION
SCHEDULE (MONTHLY)
PRODUCTION
SUPERVISOR
ORDER
CURRENT GRANTS CUSTOMERS,
INVENTORIES DISTRIBUTORS
DAILY PRODUCTION
SCHEDULE (WEEKLY) Quantity/time 230M Sq Ft/Mo
AGGREGATED
DEMAND
DEMAND
(MONTHLY)
SALES & MANAGEMENT CUSTOMER FORECASTS
OPERATIONS PROCESS (QUARTERLY)
PLANNING
CUSTOMER
CAPACITY FORECAST SERVICE
(MONTHLY) REPS ORDERS
MASTER PRODUCTION
SCHEDULE (MONTHLY)
PRODUCTION
SUPERVISOR
ORDER
CURRENT GRANTS CUSTOMERS,
INVENTORIES DISTRIBUTORS
DAILY PRODUCTION
SCHEDULE (WEEKLY) Quantity/time 230M Sq Ft/Mo
Frequency 12 Trucks/Day
CALENDARING WRAPPING Lot Size 648K Sq Ft
SLITTING CHOPPING
BONDING PACKAGING
(3) 5
(3) 5
Transp time 3 Days
(4) 6 LABELING 4
Invtry 3650 R Invtry 4000 Invtry 322M sq Ft
Eff Capac 8.9
Eff Capac 10.3 Eff Capac 29 Eff Caac 200
TAKT 8.3 Days 21 Days 7 Days 42
# TAKT 7.2 # TAKT 24 TAKT 120
(Master Rolls/Hr) SKUs
200
SKUs
1000 # SKUs 2,000
(Bonded Rolls/Hr) (Slit Rolls/Hr) (Cut Rolls/Hr)
Utilization 93% Utilization 70% Utilization 83% Utilization 60%
Lead time 17 Min Lead time 10 Min Lead time 10 Min Lead time 8 Min
Yield 87% Yield 98% Yield 100% Yield 100%
Reliability 98% Reliability 95% Reliability 98% Reliability 98%
UPtime 61% UPtime 69% UPtime 98% UPtime 98%
# SKUs 200 # SKUs 1000 # SKUs 1800 # SKUs 2000
Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll Batch size 1 Cut Roll
EPEI 13 days EPEI 7 days EPEI 7 days EPEI 7 days
C/O time 45 Min C/O time 5 Min C/O time 0 C/O time 0
C/O loss ~0 C/O loss ~0 C/O loss 0 C/O loss 0
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
Integrating material flow and information flow on the same map helps to
uncover Capacity Constraints
The timeline appears on the bottom of the VSM, below the material flow
and data boxes
It is a square wave – contrasts value-add time with non-value-add time
Normal convention – NVA time is the high part of the wave, VA time the
low portion
3 M 42 Days
21 Days 7 Days
17 Min 10 Min 10 Min 8 Min
The timeline highlights all those wastes that add time (most of them do!)
In many assembly processes, NVA is 90% of total time
In process plants it can exceed 99%
CALENDARING WRAPPING
SLITTING CHOPPING
BONDING PACKAGING
(3) 5
(3) 5
(4) 6 LABELING 4
Invtry 3650 R Invtry 4000 Invtry 322M sq Ft
Eff Capac 8.9 Eff Capac 10.3 Eff Capac 29 Eff Capac 200
Days 21 Days 7 Days 42
TAKT 8.3 TAKT 7.2 TAKT 24
# # TAKT 120
(Master Rolls/Hr) 200 1000 # SKUs 2,000
SKUs (Bonded Rolls/Hr) SKUs (Slit Rolls/Hr) (Cut Rolls/Hr)
Utilization 93% Utilization 70% Utilization 83% Utilization 60%
Lead time 17 Min Lead time 10 Min Lead time 10 Min Lead time 8 Min
Yield 87% Yield 98% Yield 100% Yield 100%
Reliability 98% Reliability 95% Reliability 98% Reliability 98%
UPtime 61% UPtime 69% UPtime 98% UPtime 98%
# SKUs 200 # SKUs 1000 # SKUs 1800 # SKUs 2000
Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll Batch size 1 Cut Roll
EPEI 13 days EPEI 7 days EPEI 7 days EPEI 7 days
C/O time 45 Min C/O time 5 Min C/O time 0 C/O time 0
C/O loss ~0 C/O loss ~0 C/O loss 0 C/O loss 0
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
3 M 42 Days
21 Days 7 Days
17 Min 10 Min 10 Min 8 Min
AGGREGATED
DEMAND
DEMAND
(MONTHLY)
SALES & MANAGEMENT CUSTOMER FORECASTS
OPERATIONS PROCESS (QUARTERLY)
PLANNING
CUSTOMER
CAPACITY FORECAST SERVICE
(MONTHLY) REPS ORDERS
MASTER PRODUCTION
RAW MATERIAL SCHEDULE (MONTHLY)
ORDERS (MONTHLY)
Frequency 12 Trucks/Day
SHEET CALENDARING WRAPPING Lot Size 648K Sq Ft
SLITTING CHOPPING
FORMING BONDING PACKAGING
6
(3) 5
(3) 5
Transp time 3 Days
(4) (4) 6 LABELING 4
Invtry 6.3M lbs Effective Invtry 2500 R Effective Invtry 3650 R Invtry 4000 Invtry 322M sq Ft
Capacity 11.8 8.9 Effective Effective Effective
SUPPLIER 2 Days 16 Days 12.6
Capacity
Days 21 Capacity 10.3
Days 7 Capacity 29 Capacity 200 Days 42
TAKT 9.5 TAKT 8.3
# # # TAKT 7.2 # TAKT 24 TAKT 120
Order Lead Frequency 1 Car/Day 6 (Master Rolls/Hr) 50 200 1000 # SKUs 2,000
1 Week SKUs SKUs (Master Rolls/Hr) SKUs (Bonded Rolls/Hr) SKUs (Slit Rolls/Hr)
Time (Cut Rolls/Hr)
Lot Size 140K lbs Utilization 80%
# SKUs 4 Utilization 93% Utilization 70% Utilization 83% Utilization 60%
Transp time 7 Days Lead time 15 Min Lead time 17 Min Lead time 10 Min Lead time 10 Min Lead time 8 Min
Yield 87% Yield 87% Yield 98% Yield 100% Yield 100%
Reliability 90% Reliability 98% Reliability 95% Reliability 98% Reliability 98%
UPtime 73.6% UPtime 61% UPtime 69% UPtime 98% UPtime 98%
# SKUs 50 # SKUs 200 # SKUs 1000 # SKUs 1800 # SKUs 2000
Batch size 1 roll Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll Batch size 1 Cut Roll
EPEI 9 days KEY
EPEI 13 days EPEI 7 days EPEI 7 days EPEI 7 days
C/O time 1 hr K = 1,000
C/O time 45 Min C/O time 5 Min C/O time 0 C/O time 0
C/O loss 2 Rolls M = 1,000,000
C/O loss ~0 C/O loss ~0 C/O loss 0 C/O loss 0 B = 1,000,000,000
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
3 M 42 Days
16 Days 12.6 Days 21 Days 7 Days NVA Time = 99 Days
15 Min 17 Min 10 Min 10 Min 8 Min VA Time = 73 Min
Takt
A measure of the rate of customer demand
Takt in German means rhythm, or drum beat
Goal is to synchronize production to customer needs
Units
Minutes (per car, per roll, per batch)
Also hours or seconds
A measure of how much time you have to produce a unit and meet
customer needs
© 2009 - LEAN DYNAMICS LLC – ALL RIGHTS RESERVED 28
TAKT TIME
Available Time
The time you plan to run, the planned work schedule
Number of shifts
Hours per shift
Deduct time for lunch and breaks
If a plant runs 16 hours per day, 5 days each week, available time would
be 80 hours per week
If production suspends for an hour each shift for lunch and breaks,
available time is 70 hours per week
Do NOT deduct for equipment downtime
Example
A salad dressing line has weekly demand of 45,000 cases for the flavors
made on that line
Three eight-hour shifts per day, 5 days per week
Production continues through lunch, breaks, shift changes
Available time = 3 x 8 x 5 = 120 hours/week
Takt = 120 hours / 45,000 cases = 9.6 seconds
So the plant must produce a case every 9.6 seconds to satisfy customer
demand
The units by which production is measured may change from step to step
In a ketchup production line
Raw materials: pounds, gallons, cases
Kitchen: gallons per minute
Bottling line: Bottles per minute (BPM)
Label applicator: BPM
Case packer: Cases per hour
Palletizer: Pallets per hour
Two considerations:
1) Use the units most directly related to equipment throughput.
2) Use the units generally used within the area (by operators,
mechanics, process engineers, lab technicians).
SLIT ROLLS or
SHEETS
Two approaches
1. Walk the line
NARROW ROLL
CHOPPER
(1' - 3')
(1) 5
Effective
Capacity 9
TAKT 8
(Slit Rolls/Hr)
Utilization 89%
Lead time 10 Min
Yield 100%
WRAPPING
SLITTING
PACKAGING
(3) 5 LABELING 4
Invtry 4000
Effective Effective
Capacity 10.3 Capacity 200
Days 7
TAKT 7.2 # TAKT 120
1000
(Bonded Rolls/Hr) SKUs (Cut Rolls/Hr)
Utilization 70%
UNIVERSAL
Utilization 60%
CHOPPER
Lead time 10 Min Lead time 8 Min
(1' - 6')
Yield 98% Yield 100%
(2) 5
Reliability 95% Reliability 98%
UPtime 69% Effective UPtime 98%
Capacity 20
# SKUs 1000 # SKUs 2000
TAKT 16
Batch size 1 roll Batch size 1 Cut Roll
(Slit Rolls/Hr)
EPEI 7 days EPEI 7 days
Utilization 80%
C/O time 5 Min C/O time 0
Lead time 10 Min
C/O loss ~0 C/O loss 0
Yield 100%
Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7
NARROW ROLL
CHOPPER
(1' - 3')
(1) 5
Effective
Capacity 9
TAKT 8
(Slit Rolls/Hr)
Utilization 89%
Lead time 10 Min
Yield 100%
WRAPPING
SLITTING
PACKAGING
(3) 5 LABELING 4
Invtry 4000
Effective Effective
Capacity 10.3 Capacity 200
Days 7
TAKT 7.2 # TAKT 120
1000
(Bonded Rolls/Hr) SKUs (Cut Rolls/Hr)
Utilization 70%
UNIVERSAL
Utilization 60%
CHOPPER
Lead time 10 Min Lead time 8 Min
(1' - 6')
Yield 98% Yield 100%
(2) 5
Reliability 95% Reliability 98%
UPtime 69% Effective UPtime 98%
Capacity 20
# SKUs 1000 # SKUs 2000
TAKT 16
Batch size 1 roll Batch size 1 Cut Roll
(Slit Rolls/Hr)
EPEI 7 days EPEI 7 days
Utilization 80%
C/O time 5 Min C/O time 0
Lead time 10 Min
C/O loss ~0 C/O loss 0
Yield 100%
Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7
3 M
7 Days
10 Min 8 Min
SLITTING
SHEET
(3) 5
FORMING
(4) 6 ROLL Effective
Capacity 10.3
Effective
Capacity 11.8 GOODS TAKT 7.2
TAKT 9.5 (Bonded Rolls/Hr)
(Master Rolls/Hr) STORAGE Utilization 70%
Utilization 80% Lead time 10 Min
AUTOMATIC
CALENDARING STORAGE &
BONDING CHOPPING
(4)
RETRIEVAL SYSTEM (3)
6 5
Effective
Capacity 8.9 Effective
Capacity 29
TAKT 8.3 TAKT 24
(Master Rolls/Hr) (Slit Rolls/Hr)
Utilization 93% Utilization 83%
Lead time 10 Min
SHEET CALENDARING
SLITTING CHOPPING
FORMING BONDING
6
(3) 5
(3) 5
(4) (4) 6
1990 1380
Effective Invtry Effective Invtry Invtry 4000
Capacity 11.8 Rolls 8.9 Rolls Effective Effective
Capacity
Capacity 10.3 Capacity 29
TAKT 9.5 Days 10 Days 8 Days 7
TAKT 8.3 TAKT 7.2 TAKT 24
# # #
(Master Rolls/Hr) SKUs
50 (Master Rolls/Hr) SKUs
200
SKUs
1000
(Bonded Rolls/Hr) (Slit Rolls/Hr)
Utilization 80% Utilization 93% Utilization 70% Utilization 83%
Lead time 15 Min Lead time 17 Min Lead time 10 Min Lead time 10 Min
Yield 87% Yield 87% Yield 98% Yield 100%
Reliability 90% Reliability 98% Reliability 95% Reliability 98%
UPtime 73.6% UPtime 61% UPtime 69% UPtime 98%
# SKUs 50 # SKUs 200 # SKUs 1000 # SKUs 1800
Batch size 1 roll Batch size 1 roll Batch size 1 roll Batch size 1 Slit Roll
EPEI 7 days EPEI 7 days EPEI 7 days EPEI 7 days
C/O time 1 hr C/O time 45 Min C/O time 5 Min C/O time 0
C/O loss 2 Rolls C/O loss ~0 C/O loss ~0 C/O loss 0
Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk Avail time 168 hr/wk
Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7 Shift schd 3x8x7
3 M
10 Days 8 Days 7 Days
15 Min 17 Min 10 Min 10 Min
In order to become more lean, you must be able to see the waste in
your process
Value Stream Mapping is a proven, effective way to do that
A well constructed VSM will enable you to see the major wastes
And clues to their root cause
The VSM provides a template for all improvement activity
Using all planned improvements to build a Future State VSM
insures that all efforts are
Coordinated
Integrated
Moving you toward a more waste-free process
Productivity Press
May 2009
(302) 239-1667
(302) 528-2700
Takt
A measure of the rate of customer demand
Takt in German means rhythm, or drum beat
Goal is to synchronize production to customer needs
Units
Minutes (per car, per roll, per batch)
Also hours or seconds
A measure of how much time you have to produce a unit and meet
customer needs
© 2009 - LEAN DYNAMICS LLC – ALL RIGHTS RESERVED 54
TAKT and CYCLE TIME
Available Time
The time you plan to run, the planned work schedule
Number of shifts
Hours per shift
Deduct time for lunch and breaks
If a plant runs 16 hours per day, 5 days each week, available time would
be 80 hours per week
If production suspends for an hour each shift for lunch and breaks,
available time is 70 hours per week
Do NOT deduct for equipment downtime
Example
A lawnmower plant has weekly demand of 2000 for a certain model
Two eight-hour shifts per day, 5 days per week
Production continues through lunch, breaks, shift changes
Available time = 2 x 8 x 5 = 80 hours/week
Takt = 80 hours / 2000 = 2.4 minutes
So the plant must produce a completed mower every 2.4 minutes to
satisfy customer demand
Takt = 2.2 min Takt = 2.2 min Takt = 2.4 min* Avail time = 80 hr/wk Customer demand
Yield = 90% Takt = 2.4 min = 2000 mowers
per week
Cycle Time
If Takt represents customer demand…….
Our process must be able to produce within that time
Cycle Time measures how long it takes to produce one unit, one
lot, one batch, etc.
If Cycle Time < Takt, we can produce faster than customer needs
If the cycle time for step 3 in the lawnmower plant is 2 minutes,
we can produce faster than needed, with about 10% spare
capacity
Utilization
A measure of how fully occupied a process step is, how busy it is
Effective Capacity
The reciprocal of Cycle Time is often called Effective Capacity
As before, it represents realistic expectations, not perfection
Utilization
A measure of how fully occupied a process step is, how busy it is
To summarize
Cycle time or effective capacity is a measure of what we can expect from
each step in our process under normal operating conditions
Take time or take rate is what each step in the process must make to meet
customer demand
If cycle time and takt time for a process step are exactly equal, that step is
perfectly synchronized to customer needs
If cycle time exceeds takt, we have a bottleneck
If cycle time is less than takt, we have some degree of excess capacity (this
is desirable)
It is up to the user to decide whether time or rate parameters make
more sense