Lean manufacturing: The Value Stream Map (VSM)

Please elaborate the VSM for the following processes, using MS Visio, and answer the questions
below.

Exercise 1: Tequila Distillation (Reposado)

Process step First Pass Yield Cycle Time (CT) Scrap (%) Shifts
(FPY)
Cooking 99.8% 72 h 0.2% 2
Pressing 100% 24 h 0 1
Fermentation 98% 70 h 2% 3
Distillation 97% 36 h 3% 3
Aging 100% 30 day (720 h) 0 3
Bottling 98.5% 2h 1.5% 1
Total 93.44% 924 h / 500 l 2.7% N/A

Please consider the following inventory (WIP = Work in process) in between processes:

 Before cooking: 1 day

 After cooking: zero
 After pressing: zero
 After fermentation: 1 day
 After distillation: 0.5 day
 After aging: 1 month
Questions:

1. Where are the bottlenecks?

FERMENTATION
2. Which actions do you propose to fix them?
Adding more than one tank in the process
3. How could you reduce inventory?
Make the warehouse bigger and make able for the tequila pass from one process to
another without being stored.
 Exercise 2: Tuna processing
Process step First Pass Yield Cycle Time (CT) Scrap (%) Shifts
(FPY)
Catching 85% 10 day 15% 3
Washing 100% 2h 0 1
Cooking 98% 12 h 2% 3
Cleaning 100% 24 h 0 3
Cutting 95% 8h 5% 3
Deeping 100% 2h 0 1
Packing in can 98% 6 h / 500 kg 2% 1
Palletizing 100% 2 h / 500 kg 0 1
Totals N/A

- Please calculate the totals and include them in the VSM

- Consider the following inventory and transportation in the process:
o After catching: 16 h of transportation to the ground
o After cooking: 2 days inventory
o After deeping: 1 day inventory

Questions:

1. Where are the bottlenecks?

CLEANING
2. Which actions do you propose to fix them?
Increase the capacity of cleaning equipment or improve methods to reduce the time
needed to clean.
3. How could you reduce inventory?
Optimize processes so that the tuna does not take so much time in storage