繪製現狀圖

CSUN - Prof. David Shternberg MSE595LM - Lean Manufacturing Example PROCESS BOX ICONS DATA BOX ICONS - C/T time - C/O time - Up time - Scrap

CSUN - Prof. David Shternberg MSE595LM - Lean Manufacturing Example Information Flow INVENTORY ICONS WITH PUSH ARROWS Material Flow

Value Stream Step 4 Current State Map - 1st View First - Show the Customer Value Stream Step 4 Current State Map - 1st View State St. Assembly 18,400 pcs/mo -12,000 “L” -6,400 “R” Tray=20 pcs. 2 Shifts

Value Stream Step 4 Current State Map - 2nd View Second - add the major Processes, Data Boxes, and Inventory Triangles Value Stream Step 4 Current State Map - 2nd View State St. Assembly 18,400 pcs/mo -12,000 “L” -6,400 “R” Tray=20 pcs. 2 Shifts I I Stamping I S. Weld # 1 I S. Weld # 2 I Assy # 1 Assy # 2 I Shipping Coils 4600 L 1100L 1600 L 1200 L 2700 L 2400 R 600 R 850 R 640R 1440 R 5 days CT=1sec. CT=39sec. CT=46sec. CT=62sec. CT=40sec. Co=0 Co=1 hr. Co=10 min. Co=10 min. Co=0 Uptime=85% Uptime=100% Uptime=80% Uptime=100% Uptime=100% 27,600 sec. avail 2 shifts 2 shifts 2 shifts 2 shifts 27,600 sec.avail EPE=2 weeks 27,600 sec.avail 27,600 sec.avail 27,600 sec.avail The data obtained is put in the data box directly beneath the process box.

Value Stream Step 4 Current State Map - 3rd View Third - Show the Material Flow Value Stream Step 4 Current State Map - 3rd View The supplier of raw material is identified with a factory icon. In this case they deliver 500 ft coils State St. Assembly Michigan Steel Co. 18,400 pcs/mo -12,000 “L” -6,400 “R” 500 Ft. Coils Tray=20 pcs. Tues & Thurs. 2 Shifts A truck icon and broad arrow indicate movement of finished goods to the customer and raw material to the site. 1X Daily I Stamping I S. Weld # 1 I S. Weld # 2 I Assy # 1 I Assy # 2 I Shipping 4600 L 1100L 1600 L Coils 1200 L 2700 L 2400 R 600 R 850 R 640R 1440 R 5 days CT=1sec. CT=39sec. CT=46sec. CT=62sec. CT=40sec. Co=0 Co=1 hr. Co=10 min. Co=10 min. Co=0 Uptime=85% Uptime=100% Uptime=80% Uptime=100% Uptime=100% 27,600 sec. avail 2 shifts 2 shifts 2 shifts 2 shifts 27,600 sec.avail EPE=2 weeks 27,600 sec.avail 27,600 sec.avail 27,600 sec.avail

Value Stream Step 4 Current State Map – 4th View Fourth - show Information Flows & Push Arrows Value Stream Step 4 Current State Map – 4th View 90/60/30 day Forecasts 6 WEEK Forecast Production Control State St. Assembly MRP Weekly Fax Daily Order Michigan Steel Co. 18,400 pcs/mo -12,000 “L” -6,400 “R” 500 ft. Coils WEEKLY SCHEDULE Tray=20 pcs. 2 Shifts Tues & Thurs. 1X Daily I Coils Stamping S. Weld # 1 S. Weld # 2 Assy # 1 Assy # 2 Shipping 5 days I I 4600 L I I I 1100R 2400 R 1600 L 2700 L 600 R 1200 L 850 R 1440 R CT=1sec. CT=39sec. CT=46sec. CT=62sec. 640R CT=40sec. Co=0 Co=1 hr. Co=10 min. Co=10 min. Co=0 Uptime=85% Uptime=100% Uptime=80% Uptime=100% Uptime=100% 27,600 sec. avail 2 shifts 2 shifts 2 shifts 2 shifts 27,600 sec.avail EPE=2 weeks 27,600 sec.avail 27,600 sec.avail 27,600 sec.avail

EPE Every part every (2 weeks)

Material Flow Icons I FIFO Assembly C/T=45 sec. XYZ Corporation C/O=30 min. 300 pieces 3 Shifts. 1 day 2% Scrap Process Box Supplier/ Customer Data Box Inventory Supermarket Mon + Wed FIFO Shipment Push Physical Finished Goods First-In-First-Out Pull to Customer

Information Flow Icons Weekly Schedule Sequenced-Pull Ball Electronic Information Flow OXOX Load Leveling Box Manual Information Flow Kanban Post Withdrawal Kanban Production Kanban Signal Kanban

General Icons Kaizen Lightning Burst Operator Buffer or Safety Stock Uptime Changeover Kaizen Lightning Burst Buffer or Safety Stock Operator “Go See” Production Schedule