200 BoxCheck

201 Box 202

Value Stream Mapping Process : Ring Eye Seal Date : Current
✘ Check Box
Check
Future Ideal
Timeline Operator

Ded. Proc. Shared Proc. Proc. Time

Verbal Info Proc. Cell Prod. Lead

Time
Weekly Orders
Production Control See Sched. Tel. Info Tel. Info

Monthly Orders
Elec. Info Man. Info
Trialco JCWPA
Monthly Forecast
Supplier/ OR Manual pull/
Customer Withdrawl

Production MRP/ Order

Control ERP Input
Other Info

Kanban Signal Production

Post Kanban Kanban

Withdrawl Kaizan Queue

2 1 1 1 1 Kanban Burst

Recieving Foundry - Foundry - Machining Deburr Inspect Recieving

Load Store / WIP Safety
Static Pour Heat Treat Leveling Stock

0X 0X
C/T : 5 C/T :10 C/T : 15 min C/T : C/T :
Inventory First in, First out
C/O : 60 min C/O : C/O : 150 min C/O : C/O :
FIFO
Avail: Avail: Avail: Avail: Avail:
Push: Push Sequenced
FPY : 100% FPY : 100% FPY : FPY : FPY :
Matl. Move Pull :
OEE/Util : OEE/Util : OEE/Util : OEE/Util : OEE/Util : OR

Shipment

External Warehouse
PLT Movement

Production Lead time Oven / Quality Problem Area

Production Cycle Efficiency Heat /Prep.

Metric / Data Box Definitions : Considerations : 22 Work day / month ; 1 shift => 7 hour (after PFD) = 7.5 Hour - 2 x 10 Min - 10 Min
T/T = Travel time L/T = Lead time C/O = Change over time C/Te = Cycle time (Oven, Equipment) Takt = Available work time per shift Define effective Work hour/day
Q/T = Queue time L/T = P/T + T/T P/T = Process time P/T = Q/T + C/T + C/O Perf = Performance Time customer demand qty. per shift x working day & calculate Takt time.
C/T = Cycle time PFD = Personal Fatigue & Delay Time C/Tt = Cycle time (Touch) FPY = First Pass Yield Av=Availability OEE = FPY * Av * Perf Record all your assumptions.
Value Stream Mapping
Process :

Queue Cycle ChangeoverTi Std. Units Processed WIP Distance to next Existing Existing Comments :
Zone Oper Step Time Time me Inventory Finished process FPY OEE
 Value Stream
Mapping Icons
MATERIAL INFORMATION
FLOW ICONS FLOW ICONS

Press

Manual Info Flow

Manufacturing
Process
Electronic Info Flow

Heat Treat
Weekly Schedule

Schedule
Manufacturing
Process Shared

Load Leveling

XYZ
Corp.
Withdrawal Kanban
Outside Sources

C/T= 25
sec
C/O= 40
2 Shifts
Production Kanban
Takt= 1s

Data Box

Signal Kanban
Inventory Box

2X per
Week

Kanban Post
Truck Shipment

PUSH Arrow Sequenced Pull Ball

Finished Goods
to Customer
Go See Production
Scheduling
FIFO

First-In-First-Out
Sequence Flow
GENERAL
ICONS

Supermarket
Kaizen Lightening Burst

Physical Pull

Buffer or
Safety Stock

Move by
Forklift
Operator

Q
Quality
Problem
Boat Shipment