VALUE STREAM MAPPING

VALUE STREAM FOLD MATRICS VALUE STREAM ROLL MATRICS

190cm WIDTH MEDICAL GAUZE LINE Effctv.Cpcty : 45 Ton/month Effctv.Cpcty : 45 Ton/month
KENDAL PLANT FACTORY Processtime : 2 days 12 hours Processtime : 3 days 15 hours
Tonage Capacity : 2 Ton/day Tot.Leadtime : 3 month 16 day13 hour Tot.Leadtime : 3 month 22 day 4 hour
Meter Capacity : 30315.7895 meters/day
WorkTime effective perDay : 18 hours
Tot.ValAdd/T : 147.12 seconds Tot.ValAdd/T : 195.51 seconds
WorkTime effective perMonth : 25 days % Cmplt/Acc : days % Cmplt/Acc : days
% OnTimeDlvry : days % OnTimeDlvry : days
Purchase PPIC
ERP ERP
MES
YarnSply. BleachSply. CoreSply. PckgSuply. Marketing Client
Cpty : kg Cpty : kg Cpty : kg Cpty : pcs
ETA : days ETA : days ETA : days ETA : days ERP

Q
Slitting Folding Fold Pckging

Q Q Cyc/T : 130m/min Cyc/T : 38.4m/min Cyc/T : 76.8m/min

Warehouse Incoming Warehouse Outgoing
Warping Weaving Rewinder Bleaching De-Watering Drying ChO/T : 0 min ChO/T : 0 min ChO/T : 0 min
MES MES
Uptime : 23.5% Uptime : 36.6% Uptime : 36.6%
1. Cotton Yarn M.Qty : 1 unit M.Qty : 2 unit M.Qty : 1 unit 1. Gauze Roll Sterile Indv.
2. Viscose Yarn 2. Gauze Roll Non-Sterile Bulk
3. Bleach Chemical Cy/T : 450 m/min Cy/T : 0.43 m/min Cyc/T :70 m/min Cyc/T : 16.6m/min Cyc/T : 700m/min Cyc/T : 100m/min 3. Gauze Fold Sterile Indv.
4. Paper Core Roller Roll Cutting Roll Pckging 4. Gauze Fold Sterile Retail
5. Pouch Sterile Packaging ChO/T : 0 min ChO/T : 0 min ChO/T : 0 min ChO/T : 0 min ChO/T : 0 min ChO/T : 0 min 5. Gauze Fold Non-Sterile Bulk
6. Paper Wrap Packaging Uptime : 6.4% Uptime : 108.9% Uptime : 41.1% Uptime : 84.4% Uptime : 4% Uptime : 28.4%
7. Inner & Carton Box
M.Qty : 1 unit M.Qty : 60 unit M.Qty : 1 unit M.Qty : 2 unit M.Qty : 1 unit M.Qty : 1 unit
Cyc/T :16.6 m/min Cyc/T:132.8m/min Cyc/T : 33.2m/min
ChO/T : 0 min ChO/T : 0 min ChO/T : 0 min
Uptime : 41.3% Uptime : 30.5% Uptime : 41.3%
M.Qty : 2 unit M.Qty : 1 unit M.Qty : 1 unit

FOLD PROCESS (perDay) 1.17 hours 19.6 hours 7.22 hours 15.22 hours 0.72 hours 5.05 hours 3.89 hours 6.58 hours 6.58 hours

FOLD LEADTIME (perMonth) 1 day,11 hours 27 days, 4 hours 10 days, 5 hours 21 days, 2 hours 1 day 7 day, 2 hours 5 days, 7 hours 9 days, 3 hours 9 days, 3 hours

ROLL PROCESS (perDay) 1.17 hours 19.6 hours 7.22 hours 15.22 hours 0.72 hours 5.05 hours 7.61 hours 5.5 hours 7.61 hours

ROLL LEADTIME (perMonth) 1 day,11 hours 27 days, 4 hours 10 days, 5 hours 21 days, 2 hours 1 day 7 day, 2 hours 10 days, 6 hours 7 days, 12 hours 10 days, 6 hours

Design Bram Revision 00 Tittle

KENDAL PLANT GAUZE LINE
Gauze Mfg LYT-G1 S-G01 LEAN SMJ Approved Standard IEEE VALUE STREAM MAPPING
Tech. Ref. Doc.No. Dwg.No. Dept. Cpny. Drawn Bram Sheets 01 Pages 02
 ACTIVITY
ACTIVITY

INSPECTION
OPERATION
CODE

TRANSPOR
MACHINE/ DISTANCE TIME

STORAGE
TATION
DESCRIPTON CATEGORY

DELAY
ACTIVITY DESCRIPTION TOOLS (METERS) (SECONDS)

0W0 Penginputan Incoming Material : Order List, Packing List COMPUTER : ERP ***** YES ***** NNVA
0W1 Penimbangan Muatan Incoming Material WEIGH-GATE : ATLS YES NNVA
0Q0 Pengendalian Kualitas Material : Isolasi atau Passed INSTRUMENTS YES NVA
0W3 Penyimpanan pada Racking Storage Material RACKING ASRS YES NNVA
0W4 Penginputan Outgoing Material sesuai Manufacturing Order COMPUTER : ERP YES NNVA
0H0 Pengiriman Material ke JobShop Produksi CONVEYOR YES YES NVA
1P0 Loading Material Yarn pada JobShop WARPING WARPING YES NNVA
1P1 Setting mesin WARPING WARPING YES NNVA
1P2 Running mesin WARPING speed 450 m/menit WARPING 1.17 jam YES VA
1Q0 Pengendalian Kualitas In-Line WARPING INSTUMENTS YES NVA
1H0 Pengiriman Output WARPING ke JobShop WEAVING CONVEYOR YES YES NVA
2P0 Setting mesin WEAVING WEAVING YES NNVA
2P1 Running mesin WEAVING speed 0.43 m/menit tiap mesin WEAVING 19.6 jam YES VA
2Q0 Pengendalian Kualitas In-Line WEAVING WEAVING YES NVA
2H0 Pengiriman Output WEAVING ke JobShop REWINDING CONVEYOR YES YES NVA
3P0 Setting mesin REWINDING REWINDING YES NNVA
3P1 Running mesin REWINDING speed 70 m/menit REWINDING 7.22 jam YES VA
3W0 Penyimpanan Work-in-Process Tunggu Proses BLEACHING MINI RACK ASRS YES NVA
3H0 Pengiriman Output REWINDING ke JobShop FLIPPER CONVEYOR YES YES NVA
4P0 Membalik Jumbo Roll dari posisi berdiri ke posisi tidur FLIPPER YES NVA
4P1 Pengkatrolan Jumbo Roll dari mesin Flipper ke BLEACHING OVERHEAD-CRANE YES YES NVA
4P2 Setting mesin BLEACHING BLEACH POT YES NNVA
4P3 Running mesin BLEACHING speed 16.6 m/menit BLEACH POT 15.22 jam YES VA
4P4 Pengkatrolan Jumbo Roll dari BLEACHING Pot ke DE-WATERING OVERHEAD-CRANE YES YES NVA
4P5 Setting mesin DE-WATERING DE-WATERING YES NNVA
4P6 Running mesin DE-WATERING speed 700 m/menit DE-WATERING 0.72 jam YES VA
4P7 Pengkatrolan Jumbo Roll dari DE-WATERING ke FLIPPER OVERHEAD-CRANE YES YES NVA
4P8 Membalik Jumbo Roll dari posisi berdiri ke posisi tidur FLIPPER YES NVA
4P9 Pengkatrolan Jumbo Roll ke Unwinder Dryer OVERHEAD-CRANE YES YES NVA
4P10 Setting mesin Natural Gas Boiler Steam NG STEAM BOILER YES NNVA
4P11 Boiling Process Steam Heating pada mesin Dryer NG STEAM BOILER YES NNVA
4P12 Setting mesin Steam Dryer Rewinder STEAM-DRYER YES NNVA
4P13 Running mesin Steam Dryer speed 100 m/min STEAM-DRYER 5.05 jam YES VA
4Q0 Pengendalian Kualitas In-Line BLEACHING - DRYING INSTRUMENT YES NVA
4W0 Penyimpanan Work-in-Process Tunggu Proses Hasil Bleach MINI RACK ASRS YES NVA
4H0 Pengiriman Output BLEACHED Jumbo Roll ke mesin SLITTER CONVEYOR YES YES NVA
5P0 Setting Mesin SLITTER SLITTER YES NNVA
5P1 Running mesin SLITTER speed 130 m/menit SLITTER 3.89 jam YES VA
5H0 Pengiriman Output SLITTER ke mesin FOLDING CONVEYOR YES YES NVA
6P0 Setting Mesin FOLDING FOLDING YES NNVA
6P1 Running Mesin FOLDING speed 38.4 m/min FOLDING 6.58 jam YES VA
6Q0 Pengendalian Kualitas In-Line FOLDING INSTRUMENT YES NVA
6H0 Pengiriman Output FOLDING ke mesin PACKAGING CONVEYOR YES YES NVA
7P0 Setting Mesin PACKAGING PACKAGING YES NNVA
7P1 Running Mesin PACKAGING speed 76.8 m/min PACKAGING 6.58 jam YES VA
7Q0 Pengendalian Kualitas In-Line FOLD Packaging INSTRUMENT YES NVA
8W0 Penginputan Incoming Finished Good sesuai Production Orders CONVEYOR YES YES NVA
8W1 Penyimpanan pada Racking Finished Goods RACKING ASRS YES NVA

Design Bram Revision 00 Tittle

KENDAL PLANT GAUZE LINE
Gauze Mfg LYT-G1 S-G01 LEAN SMJ Approved Standard IEEE PROCESS ACTIVITY MAPPING
Tech. Ref. Doc.No. Dwg.No. Dept. Cpny. Drawn Bram Sheets 02 Pages 02
 ACTIVITY
ACTIVITY

INSPECTION
OPERATION
CODE

TRANSPOR
MACHINE/ DISTANCE TIME

STORAGE
TATION
DESCRIPTON CATEGORY

DELAY
ACTIVITY DESCRIPTION TOOLS (METERS) (SECONDS)

0W0 Penginputan Incoming Material : Order List, Packing List COMPUTER : ERP ***** YES ***** NNVA
0W1 Penimbangan Muatan Incoming Material WEIGH-GATE : ATLS YES NNVA
0Q0 Pengendalian Kualitas Material : Isolasi atau Passed INSTRUMENTS YES NVA
0W3 Penyimpanan pada Racking Storage Material RACKING ASRS YES NNVA
0W4 Penginputan Outgoing Material sesuai Manufacturing Order COMPUTER : ERP YES NNVA
0H0 Pengiriman Material ke JobShop Produksi CONVEYOR YES YES NVA
1P0 Loading Material Yarn pada JobShop WARPING WARPING YES NNVA
1P1 Setting mesin WARPING WARPING YES NNVA
1P2 Running mesin WARPING speed 450 m/menit WARPING 1.17 jam YES VA
1Q0 Pengendalian Kualitas In-Line WARPING INSTUMENTS YES NVA
1H0 Pengiriman Output WARPING ke JobShop WEAVING CONVEYOR YES YES NVA
2P0 Setting mesin WEAVING WEAVING YES NNVA
2P1 Running mesin WEAVING speed 0.43 m/menit tiap mesin WEAVING 19.6 jam YES VA
2Q0 Pengendalian Kualitas In-Line WEAVING WEAVING YES NVA
2H0 Pengiriman Output WEAVING ke JobShop REWINDING CONVEYOR YES YES NVA
3P0 Setting mesin REWINDING REWINDING YES NNVA
3P1 Running mesin REWINDING speed 70 m/menit REWINDING 7.22 jam YES VA
3W0 Penyimpanan Work-in-Process Tunggu Proses BLEACHING MINI RACK ASRS YES NVA
3H0 Pengiriman Output REWINDING ke JobShop FLIPPER CONVEYOR YES YES NVA
4P0 Membalik Jumbo Roll dari posisi berdiri ke posisi tidur FLIPPER YES NVA
4P1 Pengkatrolan Jumbo Roll dari mesin Flipper ke BLEACHING OVERHEAD-CRANE YES YES NVA
4P2 Setting mesin BLEACHING BLEACH POT YES NNVA
4P3 Running mesin BLEACHING speed 16.6 m/menit BLEACH POT 15.22 jam YES VA
4P4 Pengkatrolan Jumbo Roll dari BLEACHING Pot ke DE-WATERING OVERHEAD-CRANE YES YES NVA
4P5 Setting mesin DE-WATERING DE-WATERING YES NNVA
4P6 Running mesin DE-WATERING speed 700 m/menit DE-WATERING 0.72 jam YES VA
4P7 Pengkatrolan Jumbo Roll dari DE-WATERING ke FLIPPER OVERHEAD-CRANE YES YES NVA
4P8 Membalik Jumbo Roll dari posisi berdiri ke posisi tidur FLIPPER YES NVA
4P9 Pengkatrolan Jumbo Roll ke Unwinder Dryer OVERHEAD-CRANE YES YES NVA
4P10 Setting mesin Natural Gas Boiler Steam NG STEAM BOILER YES NNVA
4P11 Boiling Process Steam Heating pada mesin Dryer NG STEAM BOILER YES NNVA
4P12 Setting mesin Steam Dryer Rewinder STEAM-DRYER YES NNVA
4P13 Running mesin Steam Dryer speed 100 m/min STEAM-DRYER 5.05 jam YES VA
4Q0 Pengendalian Kualitas In-Line BLEACHING - DRYING INSTRUMENT YES NVA
4W0 Penyimpanan Work-in-Process Tunggu Proses Hasil Bleach MINI RACK ASRS YES NVA
4H0 Pengiriman Output BLEACHED Jumbo Roll ke mesin ROLL CONVEYOR YES YES NVA
5P0 Setting Mesin ROLLING ROLLING YES NNVA
5P1 Running mesin ROLLING speed 16.6 m/menit ROLLING 7.61 jam YES VA
5H0 Pengiriman Output ROLL ke mesin CUTTING CONVEYOR YES YES NVA
6P0 Setting Mesin CUTTING CUTTING YES NNVA
6P1 Running Mesin CUTTING speed 132.8 m/min CUTTING 5.5 jam YES VA
6Q0 Pengendalian Kualitas In-Line CUTTING INSTRUMENT YES NVA
6H0 Pengiriman Output CUTTING ke mesin PACKAGING CONVEYOR YES YES NVA
7P0 Setting Mesin PACKAGING PACKAGING YES NNVA
7P1 Running Mesin PACKAGING speed 33.2 m/min PACKAGING 7.61 jam YES VA
7Q0 Pengendalian Kualitas In-Line ROLLING Packaging INSTRUMENT YES NVA
8W0 Penginputan Incoming Finished Good sesuai Production Orders CONVEYOR YES YES NVA
8W1 Penyimpanan pada Racking Finished Goods RACKING ASRS YES NVA

Design Bram Revision 00 Tittle

KENDAL PLANT GAUZE LINE
Gauze Mfg LYT-G1 S-G01 LEAN SMJ Approved Standard IEEE PROCESS ACTIVITY MAPPING
Tech. Ref. Doc.No. Dwg.No. Dept. Cpny. Drawn Bram Sheets 02 Pages 02