Homework/Assignment 2

Full Name: Tô Bảo Trân – IEIEIU18103

Trần Thị Thanh Thảo – IEIEIU18136
Đỗ Trung Hiếu - IEIEIU18026
Phạm Tuấn Phát - IEIEIU17021
Đỗ Thị Hồng Nhung - IEIEIU17025
Lê Thị Hạnh Tiên - IEIEIU17006
Nguyễn Hồng Bảo Phúc - IEIEIU18153
Lê Bảo Trân - IEIEIU18101
Ngô Nguyễn Thanh Sang - IEIEIU18077

Group number: 10
1. Wheels Inc. produces machines for the bicycle production industry around the
world. They have a production facility in the Netherlands, with which they
cater to the higher-end product range. In the facility, the production process
go through 1 stamping, 2 processes, 1 assembly as next map. What is your
comment, improvement plan?

Total NVA time is 18 days

Total VA time is 24.5 days or can be educe to 16.5 days
Total Lead Time is 42.5 days (with 24.5 days VA time) or 34.5 days (with 16.5 days VA
time)
Improvement:
- Proportion of NVA time is 42.4% with 24.5 days total VA time. If reducing total VA time
is taken to 16.5 days, the proportion of NVA time will be increase to 52%. It is
acceptable that the NVA time should be reduced to eliminate the waste.
- NVA time of Process steps and stamping is long in comparison with the NVA time that
remained. There are some factors that can affect to this long-time taking such as:
transportation, long waiting time of outsourcing of the stamping phase for manufacturing
the process phase. Therefore, outsourcing should be optimized carefully to improve the
schedule and forecasting demand.
- NVA time could be affected by the workforce, specifically the motion of the employee
due to the working condition and poor consistency working method. Therefore, the
company should arrange the facility layout more convenient and release training
program for employees.
2. Literature Review: Your group shall review and write at least 20 key points
from the following attached papers (This will serve as a summary for
interdisciplinary studies and to develop your skills in writing a literature
review)
- After week 2, we have learned about the Value Steam Mapping and the Simulation
based VSM. For better to understand, we have already studied about what is simulation
too.
- Firstly, the Value Stream Mapping (VSM) is a lean technique used to document,
analyze and improve the flow of information or materials required to produce a product
or service for a customer. The team walks through the manufacturing system and
documents facts such as cycle times, buffer sizes and personnel requirements which
are then turned into a map which describes the system with standardized icons. When a
map of the current situation is documented a parallel map is developed within the team
which instead describes the ideal future state. This future state is used as a base for
prioritizing improvement activities, so called kaizen events. The strengths with VSM are:
Fast and easy to carry out; Cheap because no special tools or computer programs are
needed; just only the main hours are spent during initial work; Easy to learn and
understand; All tools needed are pen and paper; Gives a good basis for discussions
and decisions; Increases the understanding for the customer, the product and
information flow and losses; Can often be performed with people directly involved in the
system with aid from a VSM experienced person. The weakness with VSM: Only the
flow of one product or product type is analysed per VSM analysis; The VSM gives only
a snapshot of the situation on the shop floor at one specific moment; The VSM map is a
rough simplification of the real situation; It is difficult to experiment with suggested new
systems and layouts.
- Secondly, the simulation variant used in this research is Discrete Event Simulation
(DES) which deals with flow of parts in a system. The streghts with simulation are: The
flow of all products can be included in the model; Not only a rough simplification; Can
analyse a time span and not only a snapshot; Dynamic course of events (complex
planning/control logic and variations and breakdowns can be included); Advanced
analyses (bottlenecks, utilization and mean sizes of buffers, standard deviations);
Possible to experiment with system changes and parameters. The weaknesses with
simulation are: Needs a lot of investment in time and money; A knowledge of simulation
methods and program have to be good; Difficulty of getting right amount of data in right
format; Often a simulation expert running a simulation project is not otherwise directly
involved in the studied system.
- Thirdly, the Simulation based value stream mapping (SBVSM) is aimed at being
able to construct dynamic values stream maps that could represent the snapshot picture
at any time during a time period and not only at one specific time. The SBVSM consists
of two parts, a simulation model and a spreadsheet. The specific programs used in this
case are AutoMod and MS Excel. The simulation model built represents a conceptual
model of a possible Pressure Die Casting (PDC) plant. The main information and data
that is used in the model concerns the products and the flow. The goal when developing
the VSM representation was to make it look as much like a standard VSM map as
possible. The same type of icons and data should be visualized. Data that is shown are
cycle times, setup times, mean storage sizes and value adding time compared to total
lead time. One big difference from a standard VSM representation is that the
spreadsheet shows all products in the system and not only one. All the information in
the VSM map is based on results, and sometimes input data, from the simulation model.
Using the simulation results as a base means that data can also be described in other
ways in addition to this. In figure 6 there are pictures showing graphs of how storage
develops over time, utilization of different resources and utilization divided into time
periods. Currently the focus when developing the visualization representation of the
VSM map has been on the flow of material. The flow of information is still to be
developed further. The information flow concerning the flow within the simulation model
is logically built into the model.
- Finally, for the future work is built on a conceptual plant which is generic for many
industries with pressure die casting process. This study will help improving the SBVSM
method. It will also try to show that the method is usable on a real plant and that the
benefits from using the method exceed the extra effort when building the model.