Extended Wiper Value-Stream Map from Factory to the Customer — Current State

Monthly forecast
Beta HQ Alpha HQ Alpha Parts
Production Production Customer Daily VOR
Beta by 11:00
Control Weekly Control Service
6 Days Customer
order
Service
MRP MRP W/House ERP Weekly B&K
1 Day stock order
Cleveland, OH Plymouth, MI Plymouth, MI by 15:00
Motors
Harlingen, TX
Weekly
Weekly Stock turn
= 10 x year
1 Shift
5.5 days
Daily scan
put away Lines = 4,000
6 Days 6 Days Defects = 98%
VOR = Daily shipping
Plant Warehouse Daily scan Stock = Weekly shipping
Production put away
Planning Daily
Control
picking
MRP WMS
Daily
Harlingen, TX picking
Harlingen, TX Twice
weekly
Daily Daily scan Daily Daily shipping
Weekly put away picking shipping 1x
Day

1x Beta Wipers 1x 2x
Day Warehouse Week Week 25 miles
Ship batch =
Beta Wipers Alpha Motors Alpha Motors outer carton
Assembly National Parts Parts DC
DC Defective = 2%

Reynosa, Mexico Harlingen, TX Detroit, MI Mansfield, MA

RM 16h 100 miles Stock turn 1,600 miles Stock turn 720 miles Stock turn
WIP 0h Ship batch = 12 x year Ship batch = 12x year Ship batch = 3x to 6x year
FG 12h = 1 pallet = outer carton = outer carton
2 Shifts 2 Shifts 2 Shifts 2 Shifts
Defective = 3% 5 Days Defective = 3% 5 Days Defective = 2% 5 Days
5 Days
EPE = 1 Week Lines = 2,500 Lines = 150,000 Lines = 50,000
Defects = 200ppm Defects = 98% Defects = 98% Defects = 98%

Box Score
P/T 6 min. (30 sec.) 35 min. 40 min. 30 min. 10 min (60 sec.) P/T = 121 min. (90 sec.)

L/T 7 days 0.25 days 30 days 6 days 30 days 3 days 3–6 months (60–120 days) 1 day 3 months (60 days) L/T = 197.25–257.25 days

%C/A 99.98% 97% 98% 97% 98% 98% 98% 98% 98% %C&A = 83.3%
(200ppm) (30,000ppm) (20,000ppm) (30,000ppm) (20,000ppm) (20,000ppm) (20,000ppm) (20,000ppm) (20,000ppm)
Steps 21 (3) 1 4 1 4 1 4 1 5 (1) Steps = 42 (4)
Extended Wiper Value-Stream Map from Factory to the Customer — Future State

Forecast Forecast
Same day
Beta HQ Alpha Parts order by 12:00
Production Order Customer deliver by 15:00
Alpha HQ Same day Service
Control Production
Control Daily order
(Sell one,
B&K
Cleveland, OH W/House Plymouth, MI order one) Motors

Plymouth, MI
Stock turn
= 100x year
1 Shift
5.5 days
Lines = 80
Daily Daily Order Defects = 99%

Dealer
Orders

1x Day
+ same
day

25 miles
1x 1x Ship batch =
Beta Wipers Day Alpha Motors Alpha Motors
National Parts
Day single wiper
Assembly Parts DC dealer roll cage
DC
Defective = 0.4%
Reynosa, Mexico Detroit, MI Mansfield, MA
RM 16h 1,600 miles Stock turn 720 miles Stock turn
WIP 0h = 20x year = 40 x year
FG 12h Mixed load Mixed load Overnight
2 Shifts Defective = 0.5% 2 Shifts Defective = 0.5% 2 Shifts
5 Days 5 Days 5 Days
Lines = 150,000 Lines = 50,000 Same day
EPE = 1 Day
Defects = 50ppm Defects = 99% Defects = 99%
Box Score
P/T 6 min. (30 sec.) 40 min. 30 min. 10 min (60 sec.) P/T = 86 min. (90 sec.)

L/T 1.2 days 4 days 18 days 4 days 9 days 1 day 3 days L/T = 40.2 days

%C/A 99.995% 99.5% 99% 99.5% 99% 99.6% 99% %C&A = 95.7%
(50ppm) (5,000ppm) (10,000ppm) (5,000ppm) (10,000ppm) (4,000ppm) (10,000ppm)
Steps 21 (3) 1 4 1 4 1 5 (1) Steps = 37 (4)