(3) VSM ICONS

ACME VSM for Steering wheel bracket Finished Good

Electronic Info
Production
assembly. The product family has two Supplier Process Process Truck Supermarket
Kanban Go See Kanban Post
Inventory cell Customer
variants (Left, Right) Withdrawal
Push Manual info
Load
Leveling Kanban Batch Signal Kanban

28/12/2021 (4) VALUE STREAM GOALS (9) COST BENEFITS

Peter • Improve the lead time
Barb Smith • Identify and eliminate the wastes ONE TIME SAVING:
Stephan
• Implement single point scheduling
(2) SPONSER: Jason • Produce to Demand ANNUAL SAVING:
Paul Doe • Flexible capacity with small production intervals

eVSM Data Prod K aizen

Cycle Time / Takt Time Chart
Qu ick Mi xMfg
11.49.00 00.4 Da ta Data 1.1
1
0.9
CT / TT Activity Takt Time Year mth Day
Product 0.8

Units
Utilization Chart
0.7 Activity Takt 2 52 20 920 Production
Min/Item

0.6
0.5
Activity Takt 1 Wk Day Min Control
Year Day Year Mth WACT
0.4
System
Units

12 920 52 20 0.3 Downtime Loss

0.2
Mth Min Wk day Changeover Loss
0.1
0 Legend
A0030 A0050 A0070 A0090 A0110 A0010 1
A0080 1 S1 - Set 1
Production A0150 1
A0090 1
P1 - L (12000.0 Item/Mth, 65.2%)
Control Set A P2 - R (6400.0 Item/Mth, 34.8%)
KProd
aizen
Da
eVSM Data
Qu ick Mi xMfg
ta11.62.00 03.0
Data
Supplier Set 1
System Customer

A0010 1
Coil 20 Customer >6400 Item
Demand <12000 Mth
20
Activity Utilization By Product
Michigan Steel Co 110 A0140 1 20 OXOX
100 Hourly
Added Unit $
0.00 90
Cost Item 2
Cumulative $ 80
Unit Cost
0
Item
2
State Street Assembly
Added Period $ 70 20
0
Cost Wk 60 Customer >6400 Item Coil Batch Bin 20
%

2
Demand <12000 Mth
50
2
1x Daily
Daily (Milk Run)
40
1
30 1
A0020 1 A0030 1 A0040 1 A0050 1 A0070 1
20 1 1
A0060 1
10
Changeover Utilization Weekly Schedule
0
2
1
Legend Shipping
A0030 A0050 A0070 A0090 A0110 Stamping Weld + Assy
Staging

Product Product
0 Item Qty Per Cycle 1 Item 0 Item Qty Per Cycle 1 Item
Tue & Thu Inventory Inventory Product 0 Item
General General Inventory
1380 Item Cycle Time 1 Sec 840 Item Cycle Time 56 Sec
Inventory Inventory General 1840 Item
CO Process Lead Inventory
Daily Changeovers 1 168 Sec Z0010
Day Time #0
Time Per Min
Changeover
10
CO Time Summary
1.50 Day 0.91 Day 2.00 Day LTVANVA 4.42 Day
Total Value
1.00 Sec 168.00 Sec 169.00 Sec
Added Cycle Time / Takt Time Chart Activity Utilization By Product
Value Added 1 100
A0030 1 A0050 1 A0070 1 A0090 1 A0110 1 A0130 1 0.07 %
001 002 Percent CT
0.9 / TT Product 90
004 0.8Chart
Utilization
80 P2
A0020 1 A0040 1 A0060 1 A0080 1 A0100 1 A0120 1 Weld
Stamping S. Weld #1 S. Weld #2 Assembly #1 Assembly #2 Shipping Changeover Total Work
0.7 70
Changeover Activity Takt Time

Min/Item
0.6 60
Coils Inventory Inventory Inventory Inventory Inventory 168 sec

%
0.5 Activity Takt 2 50
Product >2400 Item Product >600 Item Product >850 Item Product >640 Item Product >1440 Item Added Unit $
Wait 5 Day Qty Per Cycle 1 Item Qty Per Cycle 1 Item Qty Per Cycle 1 Item Qty Per Cycle 1 Item Qty Per Cycle 1 Item 0.00 0.4 40
Inventory <4600 Inventory <1100 Inventory <1600 Inventory <1200 Inventory <2700 Cost Item Activity Takt 1
Cumulative $ Cumulative $ Cumulative $ Cumulative $ Cumulative $ Cumulative $ Cumulative $ 003 0.3 30 P1

Unit Cost 0.00 Item Cycle Time 1 Sec Unit Cost

0
Item Cycle Time 39 Sec Unit Cost
0
Item Cycle Time 46 Sec Unit Cost
0
Item Cycle Time 62 Sec Unit Cost
0
Item Cycle Time 40 Sec Unit Cost
0
Item 0 WACT
Unit Cost Item
0.2 20
Added Unit
0.00
$ Added
0.00 $
Item
Added Unit
0.00
$ Added
0.00 $
Item
Added Unit
0.00
$ Added
0.00 $
Item
Added Unit
0.00
$ Added
0.00 $
Item
Added Unit
0.00
$ Added
0.00 $
Item
Added Period
0
$ Welder Changeov er Loss Changeov er Utilization
Cost Item Unit Cost Cost Item Unit Cost Cost Item Unit Cost Cost Item Unit Cost Cost Item Unit Cost Cost Wk 0.1 10
Added Period $ Added $ Added Period $ Added $ Added Period $ Added $ Added Period $ Added $ Added Period $ Added $ Uptime
0 Period Cost
0
Wk 0 Period Cost
0
Wk 0 Period Cost
0
Wk 0 Period Cost
0
Wk 0 Period Cost
0
Wk 0 Legend 0
P2
P1
Legend
Cost Wk Cost Wk Cost Wk Cost Wk Cost Wk
A0030 A0050 A0030 A0050
Associates 1 Staff Associates 1 Staff Associates 1 Staff Associates 1 Staff Associates 1 Staff
Cumulative $ Cumulative $ Cumulative $ Cumulative $ Cumulative $
0 0 0 0 0
Unit Cost Item Unit Cost Item Unit Cost Item Unit Cost Item Unit Cost Item
Min CO CO
Activity Time 460 Changeovers 1 Changeovers 1 002
Day Day Day
CO 001 Time Per Min Time Per Min
Changeovers 1 10 10 Welder
Day Changeover CO Changeover CO
Time Per Hr Stamping Downtime Uptime
1 20 %
Changeover CO Changeover Percent
Downtime
15 %
Percent
EPEI=2 weeks

Z0010
#0
Time Summary
5.00 Day 7.61 Day 1.85 Day 2.66 Day 2.00 Day 4.50 Day LTVANVA 23.62 Day
Total Value
1.00 Sec 39.00 Sec 46.00 Sec 62.00 Sec 40.00 Sec 188.00 Sec
Added
Value Added
0.01 %
Percent

(8) METRICS (6) IMPROVEMENT ACTION PLAN Not Started In progress Completed Past Due A0020
all
Pace
maker
Loop
Pacemaker Loop
A0102
all

Stamping
loop Stamping Loop
A0120
all

Supplier
loop Supplier Loop

A0030 1 A0050 #2 A0105 #2 A0130 #4

A0010 #4 Z0010 #4
Establish Pull at Coil
Continuous flow from Establish Finish Good
Establish Stamping Pull supplier with daily

•
Single weld assembly Pull Single
Start delivery End

Lead Time: EPEI: Reduce the stamping change over from 1 hr to less than 10 min Time
Now
e VSM D a ta
Wi z Pro j e ct
1 1.6 2.0 0 0 3.
0
0 Day Duration 2 mth Duration 2 mth Duration 2 Mnth Duration 2 mth

•
A0040

CS: 23.6 days CS: 2 weeks Create continuous flow from weld to assembly to eliminate the WIP accumulation

Fig 2
Kaizen to 168 sec A0100 #2 A0110 #2

Implement Pull
Reduce stamping C/O
Duration 2 mth schedule for material
time below 10 min
Handler

• Design material handler route

A0080 3 Duration 1 mth Duration 1 Mnth

FS: 4.4 days FS: 1 shift Eliminate Weld C/O

Duration 1 mth Description Project Schedule

• Improve OEE of weld #2 station A0090

Achieve 100% Uptime

welder #2
4

Pace maker Loop

•
Continuous flow from weld assembly
C/O Time Max Station Create supermarket after stamping to establish pull
Duration 1 mth

Kaizen to 168 sec

Establish Finish Good Pull

Utilization
•
Eliminate Weld C/O
CS: 60 Min Improve stamping change over Achieve 100% Uptime welder #2
Implement Pull schedule for material Handler

CS: 103 %
Year Year Week Day

Units
Reduce the stamping batch size from 300 to 150 Stamping loop
52 12 5 8 Gantt

FS: 10 Min Week Mnth Day Hr Chart

Establish Stamping Pull

Reduce stamping C/O time below 10 min

FS: 93% • Implement pull at coil supplier with daily shipment and 1.5 days of RM inventory Supplier loop
Establish Pull at Coil supplier with daily delivery
Time Now

Start To End
0 1 2 3 4 5 6 7 8 9
Legend
Mnth

(1) Define Value Stream (2) Gain management (3) Review Lean (4) Define value (5)Draw current (6) Improvement (7) Design Future (8) Metrics (9) Cost benefits
commitment Principles stream goals state map Action plan state map
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