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Original Cu Keystone VSM

This document provides a current state value stream map for the keystone jack assembly process. It shows the flow of materials and information across multiple work cells and suppliers. Key points include: - The process involves PCB cutting, contact base assembly, IDC lug assembly, keystone assembly, labeling, packing, and quality checking before shipping. - Some processes are done in-house while others are outsourced, with opportunities identified to eliminate subcontracting for certain variants. - The process produces 48 variants of keystone jacks to meet demand of 330,000 per month on average but 408,000 per month maximum, with a takt time of 3.73 seconds.

Uploaded by

Rounak Majumdar
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47 views18 pages

Original Cu Keystone VSM

This document provides a current state value stream map for the keystone jack assembly process. It shows the flow of materials and information across multiple work cells and suppliers. Key points include: - The process involves PCB cutting, contact base assembly, IDC lug assembly, keystone assembly, labeling, packing, and quality checking before shipping. - Some processes are done in-house while others are outsourced, with opportunities identified to eliminate subcontracting for certain variants. - The process produces 48 variants of keystone jacks to meet demand of 330,000 per month on average but 408,000 per month maximum, with a takt time of 3.73 seconds.

Uploaded by

Rounak Majumdar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
You are on page 1/ 18

TITLE:

Value stream mapping


Department :

Methods

MRP BRIDGE GENERATE PRODUCTION ORDER

PLANNING
SCHEDULING + RELEASE
3 MOVE ORDER FOR SF

PCB CUTTING (2 TYPES)-CAT 5 &


CAT 6
:2
SHIFT : 2
K.E : 75%

3300

REJECT=NO DATA
BATCH = 2*250=500 (NEW)
2000 (OLD)
C.T = 2.2 S
P.T = 1100 S (NEW),
4400 S (OLD)
IMPORTED TAIWAN
(IDC,PCB,CONTACTS)

CONTACT BASE ASSY (1 TYPE)


MACHINE :1

LOCAL VENDOR
0

:1
SHIFT: 2

POSIBILITY OF
SUPERMARKET FOR SUBASSY.

REJECT RATE= 6,1%


UP TIME : 75%
CT= 2.75 S
PT = 1375 S

RM STORAGE

INHOUSE
IDC LUG ASSY (2 TYPES)
RM StORAGE

KEYSTONE ASSY

2 MACHINE

MACHINE (OLD)
:1

: 1RM STORES 12:30


PM

300000 (EXPORT)

SHIFT: 2

SHIFT:2

25000 (DOMESTIC)

UP TIME: 80%

UP TIME: 80%

REJECT RATE: 1.2%


3000 mts

RANGE B

REJECT RATE: 1.5%

CT=5 /2 = 2.5 S

CT= 5.12 S

PT=2500 S

PT:

29.5 D

ELIMINA
CONTRA
FOR
L

0.24 D

(OLD MACHINE)

DIGILINK

3000 UNITS

2.75 S

29.5 D

0.5 D
5.12 D

0.24 D

I4I

2.75 S

DOM. + EXPO. (80%)


2 VARIANT

TITLE: Current State VSM for Keystone Jack assembly


Prepared By:

Cell : Keystone

State : Current
Reviewed By :

Rounak Majumdar

Manishkumar Salodkar

DOC NO.:

F/VSM/01

DATE:

REV.NO . A

5/3/2016

ethods

CLASSIFICATION:

PAGE: 1 OF 1

Template

CURRENT STATE MAP OF ASSY KEYSTONE JACK


BRIDGE

PLANT ORDER
BOOKING
MOVE ORDER FOR FG

FORECAST (CHINA VIA MAIL)


EMAIL

20%
ASSY, LABELLING +
TESTING (100%)
MACHINE (NEW)

TESTING (OPPORTUNITY)

:1

:1

SHIFT:2

REJECT RATE: 0.30%

SHIFT 2

GOES TO PATCH PANEL

REFERENCE (SR#):

REJECT RATE: 2.42%

1800

CT = 7.1 S

UP TIME : 70%

POSIBILITY OF
SUPERMARKET BEFORE
PACKING

PT:

CT = 2.75 S
PT :

SUB-CONTRACTOR

INHOUSE

EXPORT ASSY DIFFERENTIATION

RM STORES

LABELLING

PACKING IN POLYBAG
KEYSTONE + ACCESSORIES +
LABELLING (AUTO M/C.)

TESTING (100%) + DOT


MARKING

PT=1 DAY

:3

PACKING IN BOX OF 50 NOS.


+ PUTTING IN SO3 BOX

: 01

: 02

CT= 2.40 S

SHIFT: 2

SHIFT: 2

SHIFT : 2

PT:

REJECT RATE:1.54%

REJECT RATE: NO DATA

REJECT RATE:NO DATA

76000

CT=7.1 S

ELIMINATION OF SUBCONTRACTED PROCESS


FOR RANGE -B &
LABELING
1D

KE :75%

1000
(5+2.1)

PT=500*7.1 = 3550 S

5.5 D

2.4 S

UP TIME : 85%

CT: 1.41 S

PT= 200*2.5 = 500 S

PT= 71 S

0.07 D

0.035 D
2.5 S

0.07 D
2.5 S

48 VARIENTS

6 (RANGE B)
+ 18 (DIGILINK, I4I)

Location : Digilink
Approved By :

1.4 S

0.035 D

2.75 S

24 VARIANT

KE : 75%

CT = 2.5 S

7.1 S

5.5 D

500

1.4 S

48 VARIENTS

COLOUR :
DC6KYSTU WT

HUBASIA

AVERAGE: 330K / MONTHLY

DC6KYSTU -WT

LOCAL

REACH DEMAND: 408K /MONTHLY

DC6KYSTUWT-C

CHINA

TAKT TIME = 3.73 S (3.03 S PEAK)

FORECAST

TRANSPORTER HUB

INDIA DC

SHOPFLOOR

FG WAREHOUSE

S03 BOX (DOM.)


QUALITY
CHECK
(SAMPLING)

SO3 PALETT(EXPO.)

HUB ASIA (2 / WEEK)


WEEKLY (FRIDAY)

DAILY

4800

8000

0.34 D

0.52 D

FZE (3 / WEEK)
CMHL (CLIPSAL)
2 X MONTHLY

PLT =
37.76 D
PT =
21.28 S
PLT =
36.26 D
PT = 9.4 S

Date:

WHITE

BLUE

YELLOW RED

PCB :

CAT5

CAT6

CAT 5

CAT6

EXPORT

GREEN

(HOUSING)

NTHLY

EAK)

RANGE B
DIGILINK
I4I

6
6

6
6

ONLY INDIA 6 REF.


CMHL,INDIA, SELA, FZE (36 REF)
ONLY INDIA 6 REF.
48 REF

COPPER PATCH CORDS

MPS=90K/MONTHLY
TAKT TIME=13.7 (10.3
FOR PEAK)
PEAK DEMAND=120K/MONTH

BRIDGE
MRP CALCULATE
(MEETING WITH FG,SFG)
GENERATE THE PR

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