2.

Map the current state – complete map
4 WeekForecast

Logistics

90 Day Forecast Daily Order

Melte Ltd
2000kg container

Weekly Fax

Parts & Co. Ltd
27.600 pcs /Month 17.600 „Type A“ 10.000 „Type B“ 20 pieces box

Weekly Schedule
2x Week

Current State MapCalculate production Leadtime and value added time
9600 A 5400 B 1740 A 980 B 1920 A 1080 B

Daily Ship Schedule

2 Shifts

1x Day

2500 A 1450 B

6200 A 3400 B

Ingots 11 days

Die-Casting
C/T = 15 Sec. C/O = 3 Hours Availability=90% EPE = 2 Weeks
27.600 Sec. avail.

PUSH

PUSH

Finishing
C/T = 30 Sec. C/O = 0 Availability=80% 2 Shifts
27.600 Sec. avail.

Machining
C/T = 54 Sec. C/O = 1 Hour Availability=60% 3 Shifts
27.600 Sec. avail.

PUSH

Assembly
C/T = 50 Sec. C/O = 0 Availability=90% 3 Shifts
27.600 Sec. avail.

PUSH

Packaging
C/T = 18 Sec. C/O = 0 Availability=95% 1 Shift
27.600 Sec. avail.

PUSH

Shipping

Value Added Time = 217 Sec. 7,0 Days

11 Days

15 Sec.

10,9 Days

30 Sec

2,0 Days

54 Sec.

2,2 Days

100 Sec

2,9 Days

XX - 1 -

Production Lead Time = 36 Days Copyright 2001 © of Kaizen® Institute of Europe. All rights reserved

18 Sec

000 cylinders/Day 17.Daily orders Supplier 12 & 14kg Cylinders Production Control Monthly Forecast Customer 30.71s 1.5s Copyright 2001 © of Kaizen® Institute of Europe.5s to 0 3.43s 0s 0s 0s 3.71 S C/O = Shift = 2 Washing C/T = 0 C/O = Shift = 2 Segregation C/T = 0 C/O = 3 Hrs Shift = 2 Cap Inspection C/T = 0 S C/O = Shift = 2 Load to Pallet C/T = 50 S C/O = 1.43 S Shift = 2 50s to 1min 43s Loading C/T = 2 M-50 S C/O = Shift = 2 @m to %)s C/T = 3 S C/O = Shift = 2 0.5s 0.5s 3. All rights reserved .000 „14kg Daily Schedule Daily 35 per pallet 2 Shifts 2 8 Daily 5 Receiving C/T = C/O = Shift = 2 7 De Palletizing C/T = 1.43 S C/O = Shift = 2 4 1 Filling Machine C/T = 3 S to 0 C/O = Shift = 2 3 Weight Test C/T = 3 S to 0 C/O = Shift = 2 6 Leak Test Cap Sealing C/T = 3 S C/O = Shift = 2 Unload Pallet C/T = 0.600 „12kg 10.

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