The customer, Chrysler Corporation, is requesting a batch of side mirrors be delivered by truck every four hours from the company you are making this value stream map for (Michigan Mirror Monopoly). Chrysler requires a total of 600 mirrors a day (300 left side and 300 right side). There is only one shift working at all of the plants.  An ERP process is used in Production Control.

The mirrors are entirely made of ABS plastic resin which comes from DuPont Chemical.  Two tons of ABS resin is shipped by train three times a day from DuPont. Each mirror consumes five pounds of ABS resin. Chrysler sends the order via email as does Michigan Mirror Monopoly to DuPont.  The ABS resin is injection molded into mirror housings with the assistance of two operators.  It takes 10 seconds to produce a mirror. It takes 30 minutes to change dies from producing left mirrors to right mirrors, which is done once a day. The entire mirror producing facility is a push system.

All companies have seven hours of work time.  Lunches and breaks are separate and make for an eight hour work day (30 minutes for lunch and two 15 minutes breaks).  Figure out the excess inventory between each process by calculating the cycle time for a 7 hour work day with an 80% uptime rate at each process.  After the mirrors are injection molded, they are sent to the paint shop which can paint a mirror every 15 seconds (sprayed and baked). Two people work in the paint shop to monitor quality. There is no changeover time for this process because the spray guns are cleaned automatically.

The painted mirrors are then assembled with the actual mirrors and electric motors and cabling.  Assembly takes 60 seconds with three operators for each mirror. Production control members visit each process personally to make sure everything stays on schedule and to expedite certain shipments. Lastly, the mirrors are packaged and shipped in containers housing 30 parts which comes to a cycle time of 30 seconds for each part (HINT: this information is needed for the future state map). 

Make a timeline of the mirror making operation with total cycle time and lead time (value added and non-value added time).

 The future state map should be a pull system and not a modified push system.