por ———E “ACME Stamping” Data Set Acme Stamping Company produces several components for vehicle assembly plants. This case concerns one product family: a steel instrument-panel bracket subassembly in two types: one each for left-hand and right-hand drive versions of the same automobile model. ‘These components are sent to the State Street Vehicle Assembly Plant (the customer). CUSTOMER REQUIREMENTS: + 18,400 pieces per month 12,000 per month of Type “LH” 6,400 per month of Type “RH” + Customer plant operates on two shifts + Palletized returnable tray packaging with 20 brackets in a tray and up to 10 trays on a pallet. The customer orders in multiples of trays. + One daily shipment to the assembly plant by truck WORK TIME: + 20 days in a month + Two shift operation in all production departments Eight (8) hours every shift, with overtime if necessary + Two 10-minute breaks during each shift Manual processes stop during breaks Unpaid lunch *Whiteboard 1 ys State Street ‘Recently 8.400 psi 12000 26400 Tray = 20 pss eior Ee “ACME Stamping” Data Set (continued) PRODUCTION PROCESSES: + Acme’s process for this product family involves stamping a metal part followed by welding and subsequent assembly. The components are then staged & shipped to the vehicle assembly plant on a daily basis. + Switching between Type “LH (left-hand drive) and Type “RH” (right-hand drive) brackets requires 1 hour changeover in stamping and 10-minute fixture change in the welding processes. + Steel coils are supplied by Michigan Steel Co. Deliveries are made to Acme on Tuesdays and Thursdays. ACME PRODUCTION CONTROL DEPARTMENT: + Receives State Street's 90/60/30-day forecasts and enters them to MRP + Issues Acme 6-week forecast to Michigan Steel Co. via MRP + Secures coil steel by weekly faxed order release to Michigan St + Receives daily firm order from State Street + Generates MRP-based weekly departmental requirements based upon customer order, WIP inventory levels, F/G inventory levels, and anticipated scrap and downtime + Issues weekly build schedules to Stamping, Welding, and Assembly processes + Issues daily shipping schedule to Shipping Department 1 Co.pa “ACME Stamping” Data Set (continued) PROCESS INFORMATION: All processes occur in the follo v 2) 3) ‘STAMPING (The press makes parts for many Acme products) = Automated 200 Ton press with coil (automatic material feed) ~ Gyole Time: second (60 pieces per minute) = Changeover time: 1 hour (good piece to good piece) 5 days of coils before stam 4,600 pieces of Type “LH” 2,400 pieces of Type “RH” finished stampings ‘SPOT-WELD WORKSTATION | (dedicated to this product family) - Manual process with one operator ~ Cycle Time: 39 seconds = Changeover time: 10 minutes (fixture change) - Reliability: 100% - Observed Inventory: 1,100 pieces of Type “LH” 600 pieces of Type “RH” ‘SPOT-WELD WORKSTATION II (dedicated to this product family) - Manual process with one operator ~ Cycle Time: 46 seconds = Changeover time: 10 minutes (fixture change) + Reliability: 80% - Observed Inventory: 1,600 pieces of Type “LH” 850 pieces of Type “RH” 19 order and each piece goes through all processes. 4) ASSEMBLY WORKSTATION | (dedicated to this product family) + Manual process with one operator = Cycle Time: 62 seconds = Changeover time: none 640 pieces of Type “RH” 5) ASSEMBLY WORKSTATION II (dedicated to this product family) + Manual process with one operator - Cycle Time: 40 seconds = Changeover tit - Observed Inventory 2.700 pieces of Type “LH” 1,440 pieces of Type “RH” 6) SHIPPING DEPARTMENT Removes parts from finished goods warehouse and stages them for truck shipment to customer.Whiteboard 2 114 State Street ‘Recently 8.400 psi 12000 26400 ei Snape = = PeWhiteboard 3 114 State Street ‘Recently 8.400 psi 12000 26400 ei Snape = = PeWhiteboard 4 State Street ‘Recently 8.400 psi 12000 26400 Tray = 20 pss Zon ei Snape (mee Teen eeWhiteboard § State Street ‘Recently 8.400 psi 12000 26400 Tray = 20 pss ei ea See SWEDE TSE ASSEN sz eid 200% jor jo" od 1 a} era Nooo [err=39 soca [er=a sans ert = 2 code fer» 4 second (10 thaw [c= 10 ines [c= 10 mines (0-8 fcio= 6 pte = OR pein = 100% pein = 605 ptine 100% tine = 100% 1 19 19 19 T°Whiteboard 6 114 caesar, ny faadopae Seco re = pr ime oy es Coils ant 46001 Sm on sa fo o a | | estas aremee eee erat tte sor eer wanna ec wanna eons ee ara aor oe eareae See ar iene = 3 78Whiteboard 7 State Street ‘Recently 8.400 psi 12000 26400 Tray = 20 pss Zon Py AFA A & & = ser fond eae fo a a fiewsm:) © focwmms] «= [ete oe a Se or Tene Sania Stceing orcas Current Statese \ = A ea A exauE A STA | &

SEE b/ Nee [SE | Nm [cm Now EET Sere Se lo | ae be we fo BE Le eee Lf eee [er=sBecconta] “°°” [errzaB eco] frei frees . Ten = 26d SAE econd [8] soeeente | assets Ma stcinde [| sosecnte Freee ae ce ‘Acme Stamping Steering Brackets Current Statepe —————EEE Future State Drawing Designing a Lean Flow +The power behind Value Stream Mapping is you always need a future state! 1 + 70% & Keep Updating. Use pencil! drawing + Material & Information flows { 4 - Basis for your Work Plan — like a “blueprint” fi tate Caratslag + Begin by drawing on Current State { + 1st iteration assumes existing steps & equipment Can move equipment, combine, take out conveyors, make minor purchases, etc. P| Peete sty ( But there is a Problem!Oca Mass Production Large Lots, Pushed Ahead, “Island” Mentality e schedule Materia schedule 7 S : | a. E EW — seu oral a == = fwareneces Ship ZI aa Mee ‘Added Time: Minutes Time in Plant: Weeks (aa = _ > Cash Goal: The MORE the FASTER the BETTER Order 8)Waste ¢ The elements of production that add no value to the product * Waste only adds cost and time Things to Remember about Waste + Waste is really a symptom rather than a root cause of the problem + Waste points to problems within the system (at both process and value stream levels) + We need to find and address causes of wastepr ————EE What Happens to a Lean Flow... ..if a machine breaks down? ..if a defective part is included with good parts? 2nd Tier Assembly Assembly process WeldingWhiteboard 41 a FRSSSTON od 114 E) = ES ae ae s oe ae, T sepa Fado pa OOF colo Woekly Schedule roe - A8Ominies _e5z>p | “12000 (=| f & Pitch =60 50020 ped 20 m8, i Eh \ bu SP w/o ZN = /x> aE ais | 2007 | scoot cor vam jot B08 for oon Today Dany [C0 thw [c= tmnt [cr 10 mintes| [co= @ pine = 5 lipsine = 100% psine= 508 pte =O Te 13 18 Te Say 76anys 1days 27 days L_teeceea L_seeconss_[ L_ssseconte _[ L_c2secone f ‘Acme Stamping Steering Brackets Current StateWhiteboard 42 =|} "San id 114 Se cong. aaa + = tg Street = od ‘etl <= ue = [=] B50 eate T stipe fbAGOpovine Wooly Schedule 460 minices wiz000 Take = Seay ee. “60 paces Tiy= 2p Pech = 6092220 pode 20 ma, 2 i Eh \ bu Dane [C0 thw [c= tmnt [cr 10 mintes| [co= @ pire 052 pine = 1008 ptine= 60% pene OE 18 Te rr 19 Samo 76a 18d a1 L_ssecond sonsconds L_Assecone _f Lessons f ‘Acme Stamping Steering Brackets Current StateWhiteboard 43 |S aE 114 +<—_ - + see Sateen ae} Le = {Bz | ‘Assembly oo T sep feaco pine Woekly Schedule rote = A80minias Zez>p | “12000 “460 pieces Tray = 20 pee Puch = 60 sec x20 ped 20 mn, AL_ 2 i Eh \ / ASSEMBLY AT SHEE Saye 76auys 18days ay seonme™ Meee L__tescond_[ L_28ceconis_[ 1_46seconde_f L_e2seconae [ ‘Acme Stamping Steering Brackets Current StateWhiteboard 44 =) ae aE 1-14 c= een ae ——— + State Street =| —— i T= = = 3 Toheme T A ToS Weekly Schedule oe = A6Onimtes Zar | 12000" ae "S800 = bcs Tig =20 pe Tones Pitch =60 50020 ped 20 m8, zi * i J ES “ STANEN Arche Swe ee Seb 2h a SEBEL op SHIPPING & zor | ‘geoou t [os Sam jor iy or Today Say 76anys 1days 27 days 2am Cs L_teeceea L__s2ceconde L_ssseconte _[ L_c2secone f ‘Acme Stamping Steering Brackets Current StateWhiteboard 45 ene ‘PRODUCTION aoa 114 =) ae = {Bz} = 00 Reale T 20 esliny [6400 pean Weely Schedule rane = AaOmimes_eszr> | “2000S ‘oO eres: “Tay = 20 pecee Zon a shy * | Pitch =60 50020 ped 20 m8, Pr == feb sae Dio Dn Rap oo A zor | ‘sgooet ms |. ome eraap\ | Sane 76a 18ns 27 dys 2s Adan [arn A L_sescout_[ es L_sssscone _f L_e2secoue f L_ so seconds _f la ‘Acme Stamping Steering Brackets Current StateWhiteboard 46 (tax | 4 eee od 14] —— ‘State Street ae MRF Sone OOF colo J SN DS, = 4 area 4 an 2D _ 480 minaces 8.400 psi 12000 ‘Acme Stamping Steering Brackets Future StateWhiteboard 47 conte = ae OOF colo = ! Gigs | 2007 same [or [Uptime » 85% To 2D _ 480 minaces State Street ‘Recently 8.400 psi 12000 ‘Acme Stamping Steering Brackets Future StateWhiteboard 48 conte a ae OOF colo = A Cole sar [or WEDD RASS. 2D _ 480 minaces State Street ‘Recently [8 a00 pine 12000 ‘Acme Stamping Steering Brackets Future StateWhiteboard 49 Bes |__[rnaron aaa 114 as cat vee sig et ae ae = oe ae, OOF colo 2D [8 a00 pine en — a= a} £223, pene 4 cas AS Vor - 2, |i ‘Acme Stamping Steering Brackets Future StateWhiteboard 410 Bes |__[rnaron aaa 114 as cat vee sig et ae ae = oe ae, OOF colo 2D [8 a00 pine en — a= i} £223, pene 4 cas 200T days & = cays jot me ‘Acme Stamping Steering Brackets Future StateWhiteboard 411 ea RE id 114 ai pera OOF colo = ar a 4 mara Ao ae ‘fa, \ 2° 1Bame Sime sot s ey = [tine = 5% Be ‘Acme Stamping Steering Brackets Future StateWhiteboard 412 ai conte Cole Sane WEDD RASS. Be ‘Acme Stamping Steering Brackets Future StateWhiteboard 4.13 Metiaan Stealco, [Day _—s 1 ak conte ae OOF colo ea [a = a nm a ma no ie 2001 Baye [or [Uptime » 85% To Same ‘Acme Stamping Steering Brackets Future StateWhiteboord 414 Metiaan Stealco. OOF colo Bane < Se To 1S days 2D ate = 260 mines “460 pieces Picch =60 see «20 pe iS 2days Saas sec. 165 sec, 166 seconde ‘Acme Stamping Steering Brackets Future State