Value Stream Mapping - Ceramic tiles Process : Ceramic tile production of Super Tile Co.

Ltd

Information Flow
Production Control
Monthly Orders
Earth
Expert Monthly Forecast

Material Flow

4
6 6 6
4 4 6 6

Recieving Spray drying Shaping/ Product

Preparation of Milling and and mixing Drying Glazing Firing
molding Finishing
Raw materials Grinding

C/T : 2 hr C/T :3 hr C/T : 6 hr C/T : 1 hr C/T : 6 hr C/T : 2 hr C/T : 2 hr C/T : 4hr

C/O : 3 hr C/O : 4 hr C/O : 3 hr C/O : 4 hr C/O : 3 hr C/O : 3 hr C/O : 2 hr C/O : 4hr

Avail: 100% Avail: 100 Avail: 99% Avail: 95% Avail: 100% Avail: 100% Avail: 99% Avail: 99%
FPY : 100% FPY : 100% FPY : 99% FPY : 98% FPY : 100% FPY : 100% FPY : 99% FPY : 99%

OEE/Util : 85% OEE/Util : 85% OEE/Util : 85% OEE/Util : 85% OEE/Util : 85% OEE/Util : 85% OEE/Util : 85% OEE/Util : 85%

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
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
C/T = Cycle time PFD = Personal Fatigue & Delay Time C/Tt = Cycle time (Touch) FPY = First Pass Yield Av=Availability OEE = FPY * Av * Perf
 ✘ Check Box
Check Check
200 Box 201 Box 202
Date : Current Future Ideal
Timeline Operator

Ded. Proc. Shared Proc. Proc. Time

Verbal Info Proc. Cell Prod. Lead

Time

Weekly Orders See Sched. Tel. Info Tel. Info

Elec. Info Man. Info

Retail
Supplier/ OR Manual pull/
Customer Withdrawl

Production MRP/ Order

Control ERP Input
Other Info

Kanban Signal Production

Post Kanban Kanban

6
Withdrawl Kaizan Queue
6 Delievery
Kanban Burst

Product Packing and

Finishing Storage Load Store / WIP Safety
Leveling Stock

0X 0X
C/T : 4hr C/T : 5hr
Inventory First in, First out
C/O : 4hr C/O : 2hr
FIFO
Avail: 99% Avail: 99%
Push: Push Sequenced
FPY : 99% FPY : 99%
Matl. Move Pull :
OEE/Util : 85% OEE/Util : 85%
OR

Shipment

Production Lead time PLT 59hr

Heat /Prep.

Define effective Work hour/day

x working day & calculate Takt time.
Record all your assumptions.
 Supertile Ltd. Break-even analysis (business)
Balance Sheet Year Total investment
Asset Amount (HKD) Amount (HKD) 1 69200000
Current Assets 2 69200000
Cash 6,000,000 3 69200000
Prepaid expenses 300,000 4 69200000
Raw matierals 200,000 5 69200000
Working in progress 300,000 6 69200000
Finsihed goods 400,000 7 69200000
Other current assets 200,000 8 69200000
200,000 9 69200000
Fixed Assets 10 69200000
Factory and office complex 50,000,000 11 69200000
Machinery 8,000,000 12 69200000
Furniture and Fixtures 200,000 13 69200000
Computer 200,000 14 69200000
Vehicles (shuttle, forklift etc) 1,800,000 15 69200000
Others (e.g. equipment in lab) 2,000,000 16 69200000
200,000 17 69200000
Total Asset 69,200,000 18 69200000
19 69200000
20 69200000
21 69200000
22 69200000
23 69200000
24 69200000
25 69200000

Monthly expense
Fixed cost 300,000
Operating Cost 100,000
Production cost 60,000

Monthly income
Revenue
Estimate to sell 12500 sq meter
of tile per month at $ 60 per sq
meter 750,000

Monthly net gain 290,000

 900000

Amount
800000
700000
600000
500000
400000
300000
200000
100000
0
0 00 00
10 20

Total cost
is (business) Quantity (q) Total cost variable cos
Net gain Different 0 300,000 0
3480000 -65720000 500 306,400 6,400
6960000 -62240000 1000 312,800 12,800
10440000 -58760000 1500 319,200 19,200
13920000 -55280000 2000 325,600 25,600
17400000 -51800000 2500 332,000 32,000
20880000 -48320000 3000 338,400 38,400
24360000 -44840000 3500 344,800 44,800
27840000 -41360000 4000 351,200 51,200
31320000 -37880000 4500 357,600 57,600
34800000 -34400000 5000 364,000 64,000
38280000 -30920000 5500 370,400 70,400
41760000 -27440000 6000 376,800 76,800
45240000 -23960000 6500 383,200 83,200
48720000 -20480000 7000 389,600 89,600
52200000 -17000000 7500 396,000 96,000
55680000 -13520000 8000 402,400 102,400
59160000 -10040000 8500 408,800 108,800
62640000 -6560000 9000 415,200 115,200
66120000 -3080000 9500 421,600 121,600
69600000 400000 10000 428,000 128,000
73080000 3880000 10500 434,400 134,400
76560000 7360000 11000 440,800 140,800
80040000 10840000 11500 447,200 147,200
83520000 14320000 12000 453,600 153,600
87000000 17800000 12500 460,000 160,000
13000 466,400 166,400
13500 472,800 172,800
14000 479,200 179,200
 Break-even Analysis - Monthly
900000 vq
Amount

800000
700000
600000 Total cost
500000
400000 f
300000
200000 v
100000
0
0 00 00 00 00 00 00 00 00 00 0 0 0 0 0
10 20 30 40 50 60 70 80 90 00 00 00 00 00
10 11 12 13 14

Quantity
Total cost variable cost (v ) Fixed cost (f) Sales revenue (vq)
Fixed cost (f) Sales revenue (vq)
300,000 0
300,000 30,000
300,000 60,000
300,000 90,000
300,000 120,000
300,000 150,000
300,000 180,000
300,000 210,000
300,000 240,000
300,000 270,000
300,000 300,000
300,000 330,000
300,000 360,000
300,000 390,000
300,000 420,000
300,000 450,000
300,000 480,000
300,000 510,000
300,000 540,000
300,000 570,000
300,000 600,000
300,000 630,000
300,000 660,000
300,000 690,000
300,000 720,000
300,000 750,000
300,000 780,000
300,000 810,000
300,000 840,000
Monthly expense
Fixed cost 300,000
Operating Cost 100,000
Production cost 60,000

Monthly income

Revenue
Estimate to sell 12500 sq
meter of tile per month at
$ 60 per sq meter 750,000

Monthly net gain 290,000

Quantity (q) Total cost (buy)

0 220,000
500 235,000
1000 250,000
1500 265,000
2000 280,000
2500 295,000
3000 310,000
3500 325,000
4000 340,000
4500 355,000
5000 370,000
5500 385,000
6000 400,000
6500 415,000
7000 430,000
7500 445,000
8000 460,000
8500 475,000
9000 490,000
9500 505,000
10000 520,000
10500 535,000
11000 550,000
11500 565,000
12000 580,000
12500 595,000
13000 610,000
13500 625,000
14000 640,000
 Variable cost
Fixed cost (buy Total cost (make) Sales revenue (vq)
(buy)
220,000 0 300,000 0
220,000 15,000 306,400 30,000 900000
220,000 30,000 312,800 60,000
220,000 45,000 319,200 90,000 800000
220,000 60,000 325,600 120,000
700000
220,000 75,000 332,000 150,000
220,000 90,000 338,400 180,000 600000
220,000 105,000 344,800 210,000
220,000 120,000 351,200 240,000 500000
220,000 135,000 357,600 270,000
220,000 150,000 364,000 300,000 400000
220,000 165,000 370,400 330,000
220,000 180,000 376,800 360,000 300000

220,000 195,000 383,200 390,000 200000

220,000 210,000 389,600 420,000
220,000 225,000 396,000 450,000 100000
220,000 240,000 402,400 480,000
220,000 255,000 408,800 510,000 0
500
0

1000
1500
2000
2500
3000
3500
220,000 270,000 415,200 540,000
220,000 285,000 421,600 570,000 Total cost
220,000 300,000 428,000 600,000
220,000 315,000 434,400 630,000
220,000 330,000 440,800 660,000
220,000 345,000 447,200 690,000
220,000 360,000 453,600 720,000
220,000 375,000 460,000 750,000
220,000 390,000 466,400 780,000
220,000 405,000 472,800 810,000
220,000 420,000 479,200 840,000
 500
1000
1500
2000
2500
3000
3500
4000

Total cost (buy)

4500
5000
5500
6000
6500
7000
7500

Total cost (make)

8000

Make or buy analysis

8500
9000
9500
10000
10500

Sales revenue (vq)

11000
11500
12000
12500
13000
Revenue

Buy

13500
Make

14000