VSM - The case of the When In doubt, Ship it Out Manufacturing

VSM - painting axle bars

When In doubt, Ship it Out Corporation (WID-SIOC) - Production Control & Logistics

• schedules March Coatings
• Schedules Minion Rework
• Schedules Karston Krylon Coaters

Daily volume = 20,000 axle bars (80 total SKUs)

Available time = 7.2 hours per day at March Coatings

Tatk time = 1.296 sec

WID-SIOC Shipping

• ship whatever is on the dock at window time
• Ship times 6 am, 10 am, noon.
• hour transit to Brighton, MI (March Coatings)
• Time to load each truck = 30 minutes

March Coatings

Receiving times: 7 am, 11 am, 1 pm

Time = 30 minutes to unload

Blast operation

Cycle time = 1.1 sec

C/O = 30 mins

FTQ = 95%

Note: Total Inventory found ahead of blast = 22,222 unpainted axle bars

Wash operation

Cycle time = 1.25 sec

C/O= n/a

FTQ = 100%

Note: Inventory found ahead of wash operation = 18,309 unpainted axle bars with another 4010 red tagged as defective

Dryer

Cycle time = 1.25 sec

C/O = n/a

Ftq = 100%

Note: Inventory found ahead of the dryer = 21,386 unpainted axle bars

Ecoat

Cycle time = 1.28

c/o = 10 minutes

Ftq = 90%

Note: Inventory found ahead of the Ecoat = 22,080 unpainted axle bars

Note: Inventory found after the Ecoat = 18,316 painted axle bars; another 2,003 painted axle bars red-tagged as "paint defects"

March Coatings Shipping

1. am. 11 am, 1 pm
2. minutes per truck

WID-SIOC receiving

1. am, noon, 2 pm
2. minutes per truck

All rework go to Minion rework

• located in Grand Rapids (1 hour transit)
• 10 minutes receiving time
• 15 minutes shipping time

Cycle time = 5 sec

C/O = 30 minutes

FTQ = 99%

Karston Krylon Coaters

• not approved by the customer / not manned normally
• not EPA for handling hazardous material.
• In House paint booth (prefers Krylon spray paint over Rust-O-Leum)
• Cycle Time = 1.23 sec
• C/O = 90 minutes
• FTQ = 100%

Dryers

- cycle time = 1.26 sec

• c/o time = 30 minutes

1.Map the value stream, including the alternate process

2. How do we make this value stream more efficient?

3. Are you meeting takt time? Yes or No?