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Aylesbury Pressings

What improvements should the management team at Aylesbury pressings be pursuing and why?

3. 5.Aylesbury pressings – classic lean sustainability After the first flush of improvements and lean thinking many companies lose focus. 4. Understand customer Understand the value streams Make value flow Pull at the customer’s rate of demand Seek perfection . Need to return to lean principles: 1. 2.

TAKT = Available time demand .Understand the value stream – Value Stream Mapping A key tool is the Value Stream Map (VSM) • Complete the value stream map and calculate the % of value added to nonvalue added time for a steering bracket • Need to know .

2s Change over time Cycle time Value added .2s v/a= 0.VSM Guide to Icons Manual Information flow Electronic Information Flow Steel supplier Blanking Outside source Internal process For full VSM workbook see Learning to See by Rother and Shook 13 Inventory Finished goods to customer Push flow C/O= 15 min Information Box C/T= 0.

Calculate Value added /total time for a steering bracket • Calculate the TAKT • Calculate the queue times for each of the piles of inventory • Add in cycle time for each VA stage (assume 60s for assembly) .

Calculate TAKT • Demand = 170/day • Time available = assume 2 shifts of 7 hrs each Takt = 840/170 = 4.94 min say 5 min .

2s = 5min 2.% VA to NVA VA = 0.2s NVA = 2500+1000+10370+1620+3115 = 18605 min % VA to NVA = (5/18605) x 100 = 0.027% Comment – this is tiny – the equivalent of 34s work in a working week of 35 hours .2+2+60 +180+60 = 302.

2s v/a= 0.VSM current state Steel supplier Monthly forecast Weekly orders Production Control MRP II Six monthly and monthly forecasts Weekly requirement Customer Daily call off weekly schedule Daily schedule 500 dispatch 623 Paint 324 C/O= zero C/T= 90min v/a= 3 min 1620 min 0 min Blanking 200 C/O= 15 min Press C/O=30 min C/T= 2s 1780 35 13 Ass nil 230 16 C/O= 5 min C/T= 60s v/a= Final ass nil C/O= zero C/T= 1 min v/a= 3115 min C/T= 0.2s 2500 min 0.2s 1000 min v/a= 10370 min 2s 60s 180s 60s .

Monthly forecast Steel supplier Weekly orders Production Control MRP II Six monthly and monthly forecasts Weekly requirement Customer Daily call off weekly schedule Daily schedule despatch Blanking C/O= Press C/O= C/T= Ass C/O= C/T= 60s v/a= Paint C/O= C/T= v/a= Final ass C/O= C/T= v/a= C/T= v/a= v/a= .