LEAN MANAGEMENT

Value Stream Mapping (VSM)

A STEEL FABRICATION COMPANY HAS RELEASED INFORMATION ON THE PRODUCTION DEMAND AS FOLLOWS:

1. PRODUCT DEMAND : 1000 PCS/WEEK
2. PRODUCTION PLANNING : PRODUCE MATERIAL REQUIREMENT TO SUPPLIER
3. PRODUCTION DEPARTMENT/MANAGER: PREPARE THE MONTHLY PRODUCTION SCHEDULE
4. SUPPLIER: CAPACITY TO DELIVER 250 SETS LOOSE PARTS PER WEEK
5. PRODUCTION LINE:

STATION	PROCESS	INVENTORY	CYCLE TIME(MIN)
1	WELDING & WASHING	250	15
2	PAINTING	20	10
3	ASSEMBLY LINE	10	20
4	UNDERCARRIAGE JOB	20	15
5	QUALITY INSPECTION	40	20
6	TRIM AND FINAL JOB	20	15
7	INSPECTION AND DELIVERY	30	30

QUESTION:

a) PREPARE CURRENT VALUE STREAM MAPPING FLOW DIAGRAM

b) PREPARE FUTURE VALUE STREAM MAPPING FLOW DIAGRAM

NOTES:

• SHOW THE TOTAL PROCESS LEAD TIME (PLT) AND PROCESS TIME(PT), BEFORE AND AFTER IMPROVEMENT.

• IMPROVEMENTS MUST FOCUS ON ELIMINATION OF NON-VALUE-ADDED ACTIVITIES WITH REDUCTION OF PRODUCTION LEAD TIME (PLT) AND PROCESS TIME (PT)

• DISCUSS THE RESULT OF THE IMPLEMENTATION.