Based on SIPOC & Value Stream Map, Do a Report$-$out on your findings:

Introduction$/$Background

Objective

Analysis $-$ use Lean Tools

This is SIPOC

Supplier:

Two suppliers providing raw materials weekly based on forecasted demand.

Input:

Orders for custom orthotics received via Gaitscan system or mail with foam imprint of customer's foot.

Customer information and order details processed by customer service department.

Process:

Personal Top Cover:

Operators receive orders and sort by date.

Walks outside printing room to pick up orders.

Preps files on computer and sets up machines.

Applies logo to top cover using two machines $($big and small$).$

Marries top covers to order baskets.

Completes orders and moves finished products to cart.

Materials Picking:

Material picker pulls cart and picks materials needed for each order.

Places materials in baskets for technicians.

Scanning:

Scanner scans orders into technician area.

Organizes orders into batches for technicians.

Technicians:

Technicians machine base of orthotic using different machines $($flat grinder, grinder, finishing grinder$).$

Experienced and moderate experience technicians pick up batches of baskets and complete machining process.

Walk to trolley to pick up baskets and return to work station.

Operate machines to machine orthotic bases according to order specifications.

Output:

Completed orthotics with machined bases.

Orders organized and ready for quality control inspection and shipping.

Customer:

Health care practitioners ordering custom orthotics for patients.

Approximately $500-600$ orders received daily, peaking at $1000$ orders per day during peak months of June and July.

Orders shipped daily as completed to meet customer demand.

This is VSM:

Customer Order Entry:

Orders received via Gaitscan system or mail.

Customer service processes orders and ensures necessary information for manufacturing.

Personal Top Cover Production:

Operators receive orders and sort.

Logo applied to top covers using two machines.

Top covers married to order baskets.

Materials Picking:

Material picker pulls cart and selects materials for orders.

Materials placed in baskets for technicians.

Scanning:

Scanner scans orders into technician area and organizes batches.

Technicians:

Technicians machine orthotic bases using various machines.

Experienced and moderate experience technicians complete machining process.

Baskets of machined bases moved to quality control and shipping.

Quality Control and Shipping:

Quality control inspects products before shipping.

Orders processed for shipping and sent to customers and health practitioners.

Step $3$: Identify Non$-$Value$-$Adding Steps:

Waiting time between process steps.

Interruptions in material picking.

Varying production rates among technicians.

Bottleneck in technicians' machining process.

Step $4$: Design Future State:

Implement standardized work procedures to improve consistency among technicians.

Cross$-$train technicians to increase flexibility and balance workload.

Improve material handling efficiency to reduce waiting time and interruptions.

Investigate options for addressing bottleneck in machining process, such as additional equipment or process optimization.

Step $5$: Implement Future State:

Train operators and technicians on standardized work procedures.

Modify layout or workflow to streamline material handling.

Monitor and analyze production metrics to identify areas for continuous improvement.

Step $6$: Review and Update:

Regularly review performance metrics and gather feedback from employees to identify opportunities for further improvement and refinement of the value stream. Update VSM accordingly to reflect changes and maintain alignment with business objectives.