You have been tasked with creating a current state Value Stream Map (VSM) for AllDaPieces’ (ADP) new lean initiative. The goal is to create a living document that will help the team better understand ADP’s processes and help identify opportunities for improvement. In addition to the VSM, prepare a tech memo describing the parts of the VSM to your boss and describing opportunities for improvement or elimination of waste.

1) Report from AllDaPieces LLC Production Manager, Carl Woburn AllDaPieces Puzzles Inc. (ADPP) is a leading manufacturer of wooden 3-D jigsaw puzzles in the United States. The company manufactures puzzles for resale bricks-and-mortar outlets such as Barnes & Noble, Toys-R-Us, and KB
Toys. The bricks-and-mortar stores (treat them as a single customer) each provide 30-day demand forecasts which generates a daily order request. They also process and ship orders directly to customers for their web partner company WoodenGames.com which sends them individual orders. Individual orders are processed daily and information is added to daily order counts.
IHaveYaWood LLC is ADPP’s primary source for raw wood planks and blocks. Twice a week, ADPP receives a box truck containing several pallets of planks (destined for the industrial jigsaw cutter) and blocks (destined for the lathing operation). Once pallets arrive, they usually sit in the warehouse area of the plant for 2 days (on average) before materials are broken down and sorted for various operations. Once a month, ADPP also receives 4 pallets of pre-printed flat boxes from local company GotchaPackaging Inc. These boxes are folded and glued in the house to contain the finished puzzle pieces. ADPP sends their suppliers weekly orders that are based upon 30 and 60-day forecasts of demand.
Annual demand is calculated by the main office (production control), which they use to generate weekly production schedules for the various operations on the floor. There are a variety of different puzzle models the plant produces. Parts for the first two operations, jig-saw, and lathe arrive from the warehouse and wait in a queue for an average of 2 hours before being processed. Each 3D jigsaw puzzle contains a combination of flatter jig-saw cut pieces, and more rounded lathe cut pieces. These two operations are the first operations in the manufacturing process and begin in parallel with each other. They also work on the pieces from the same model simultaneously. Pieces for individual puzzles move from the jig-saw and lathe and are combined into a single moving conveyor tray. Each tray only contains pieces for a single puzzle (the inventory unit of interest, not individual puzzle pieces). The data for the jig-saw operation to make all the pieces for a single puzzle is [ C/T = 30 seconds; P/T = 25 seconds; C/O = 20 minutes;
Uptime = 75%]. The data for the lathe operation is [C/T = 70 seconds; P/T = 30 seconds; C/O = 10 minutes; Uptime = 95% ]. At any given point in time, there are 50 puzzles WIP inventory between the jig-saw/lathe and the next operation downstream and they way there for approximately 1.1 hours before starting the sanding operation.
The next operation is the sanding operation. The puzzle from each tray is dumped into a rotating drum of sand to give the pieces a nice, velvety finish. After the process is complete, the puzzle pieces are removed from the drum by hand and the sand blown off with an air hose. They are replaced in the tray and the next tray is then processed in the same way. Data for the sanding operation is [ C/T = 120 sec; P/T 100 sec; C/0 = 0 minutes; Uptime = 100%]. At any given time, only 4 puzzles WIP inventory are between the sanding operation and the next operation downstream
where they wait only an average of 0.15 hours in the queue.
Next, the tray proceeds through a machine that applies a coat of varnish to the pieces as the tray moves through it.
The varnish is baked onto the pieces as they exit the machine and they come out dry. The operator only has to monitor the process and make sure nothing goes wrong. Data for the varnish operation is [C/T = 45 sec; P/T = 45 sec; C/O = 20 minutes; Uptime = 50%]. At any given point in time, there are 15 puzzles WIP inventory between the varnish station and the next operation where they wait an average of 4.5 hours in a queue to await packaging.