Value Stream Mapping

VSM Inc. produces several aftermarket components for motorcycle repair and
replacement companies. This example investigates one Kawasaki product
family: progressive suspension forks in two types: model #VN1500 and VN1600.
These components are sent to two customers (1) supplies requests East of the
Mississippi River (customer A) and (2) supplies requests West of the Mississippi
River (customer B). Customer A & B receive a 50/50 split of each component.

Customer A & B Requirements:

 1980 pieces per month
- 1200 per month of Type “VN1500” and 780 per month of Type “VN1600”
 Customer plant operates on two shifts
 Palletized returnable tray packaging with 5 forks in a tray and up to 10 trays
on a pallet.
 The customer orders in multiples of trays.
 One daily shipment to each distribution center (Customer A & B) by truck.
Work Time:
 22 days in a month
 Two shift operation in all production departments
 Eight (8) hours every shift, with overtime if necessary
 Two 15-minute breaks during each shift
 Manual processes stop during breaks

Production Processes:
 VSM Inc. process for this product family involves milling a metal part followed
by welding, painting and subsequent assembly and inspection. The
components are then staged and shipped to Customers A & B on a daily basis.
 Switching between Type “VN1500” and Type “VN1600” suspension forks
requires a 60-minute changeover in milling and a 10-minute fixture change in
welding and a 40-minute changeover in painting.
 Raw materials are supplied by Urbana Metal Co.
 Deliveries are made to VSM Inc. on Wednesday with lead time of 10 days.
 One daily shipment to each customer distribution center by truck.
VSM Inc. Production Control Department:
 Receives East and West Distributor’s monthly forecasts and enters into MRP
Issues VSM Inc. 6-week forecast to Urbana Metal Co. via MRP
 Secures raw materials by weekly FAXed order to Urbana Metal Co.
 Issues weekly build schedule to Milling, Welding, Painting, &
Assembly/Inspection (manual system)
 Issues daily shipping schedule to Shipping Department (manual system)
Process Information: All processes occur in the following
order - each piece goes through all processes.``
1) Milling (The mill is semi-Automated)

 Cycle Time: 10 minutes

 Changeover time: 1 hour (good piece to good piece)
 Machine reliability: 90%
 Observed batch size:
160 pieces of type “VN1500” finished millings
100 pieces of Type “VN1600” finished millings

2) Welding Workstation (dedicated to this product

family)
 Manual process with one operator
 Cycle time: 150 seconds
 Changeover time: 10 minutes (fixture change)
 Reliability: 100%
 Observed batch size:
120 pieces of Type “VN1500”
75 pieces of Type “VN1600”
3) Painting Workstation
(dedicated to this product family)
 Manual process with one operator
 Cycle Time: 300 seconds
 Changeover time: 40 minutes
(fixture change)
 Reliability: 95%
 Observed batch size:
100 pieces of Type “VN1500”
60 pieces of Type “VN1600”
5) Shipping Department
Removes parts from finished goods
warehouse and stages them for truck
shipment to customer A & B.
© 2009 RLM & Associates LLC
4)Assembly & Inspection Workstation
(dedicated to this product family)

 Cycle time: 165 seconds
 Changeover time: none
 Reliability: 100%
 Observed batch size:
240 pieces of Type “VN1500”
150 pieces of Type “VN1600”
8/14/201
6
5