Consider the manufacturing system description (PDF). This document contains explanation of the XYZ company producing two different products (Product 1 and Product 2) on three different locations (Plant 1, Plant 2, and Plant 3). You should develop (draw) the current-state Value Stream Map of this company production process. Follow those guidelines:

1. Use standard symbols for Value Stream Map.
2. Include both material flow and information flow.
3. Complete the process attributes in terms of cycle times, waiting times, and any other data provided.
4. Include quantities of inventories on each location.
5. Include frequency of transport operations.
6. Use Visio for drawing the map (Visio has a VSM template, if not available directly, search for it).
7. Summarize the current-state VSM in term of waste identification (in one paragraph).
8. After drawing the VSM map, analyze applicability of continuous flow methods in this process. Your analysis should be one paragraph long.

Here's the pdf pages:

iii. Raw materials at each plant are supplied by various vendors. Raw materials are delivered on a daily basis. XYZ Production Control Department i. Receives ABC Carpet's 90/60/30 day forecasts and enters them into manufacturing resource planning (MRP). ii. Issues XYZ's 6 week forecast to ChemCo Supplier via MRP. iii. Secures raw materials by weekly faxed order release to ChemCo Supplier. iv. Generates MRP-based, weekly departmental requirements based on customer orders. v. Issues weekly build schedules to Plants 1,2 , and 3. vi. Issues daily shipping schedule to shipping department at Plants 1,2 , and 3. Process Information All processes occur in the following order with Products 1 and 2 going through all processes. Plant 1 Receiving i. Raw material is shipped in by pipe, rail, and truck. ii. Raw material is stored on-site in tanks. iii. Production of some raw materials is on-site. Plant 1 i. The plant makes the same material for Products 1 and 2. ii. Cycle time is 12 days. EMGT 6500 iii. No changeover time is required. iv. Process reliability is 90%. v. Yield is 95%. vi. First pass yield is 87%. vii. Shut down for 3 weeks every 18 months to refurbish the process. viii. Observed inventory: A. 5 days of hydrogen cyanide (HCN) (in tank). B. 0 days of propane (in pipe). C. 30 days of platinum (catalyst). Plant 1 Shipning i. Products 1 and 2 are shipped out by barge and rail to Plant 2(83%) and to customers (17%) by rail and truck. ii. Products 1 and 2 are stored on-site in tanks before shipment. Plant2 Receiving i. Products 1 and 2 are shipped in by barge and rail. ii. Products 1 and 2 are stored on-site in tanks before use. Plant 2 i. The plant makes the same material for both Products 1 and 2. ii. Cycle time is 30 days. iii. Two hour changeover time is required. iv. Process reliability is 82%. v. Yield is 85%. vi. First pass yield is 68%. vii. Shut down for 2 weeks every 24 months to refurbish the process. viii. Observed inventory: A. 25 days of Product 1 (in tank). B. 12 days of Product 2 (in tank). C. 30 days of mixture 3Z4 (in tank). EMGT 6500 i. Products 1 and 2 are shipped out by rail and truck. ii. Products 1 and 2 are stored on-site in tanks before shipment. Plant 3 Receiving i. Products 1 and 2 are shipped in by rail and truck. ii. Products 1 and 2 are stored on-site in tanks before use. iii. Observed inventory: A. 35 days of Product 1 (in tank). B. 32 days of Product 2 (in tank). Plant 3 i. The plant makes a different item for both Products 1 and 2. ii. Cycle time is 30 days. iii. Eight hour changeover time is required. iv. Process reliability is 72%. v. Yield is 75%. vi. First pass yield is 62%. vii. Shut down for 3 weeks every 18 months to refurbish the process. viii. Observed inventory: A. 35 days of Product 1 (in warehouse). B. 32 days of Product 2 (in warehouse). Plant 3 Shipning i. Products 1 and 2 are shipped out by rail and truck. ii. Products 1 and 2 are stored on-site in warehouses before shipment. iii. Raw materials at each plant are supplied by various vendors. Raw materials are delivered on a daily basis. XYZ Production Control Department i. Receives ABC Carpet's 90/60/30 day forecasts and enters them into manufacturing resource planning (MRP). ii. Issues XYZ's 6 week forecast to ChemCo Supplier via MRP. iii. Secures raw materials by weekly faxed order release to ChemCo Supplier. iv. Generates MRP-based, weekly departmental requirements based on customer orders. v. Issues weekly build schedules to Plants 1,2 , and 3. vi. Issues daily shipping schedule to shipping department at Plants 1,2 , and 3. Process Information All processes occur in the following order with Products 1 and 2 going through all processes. Plant 1 Receiving i. Raw material is shipped in by pipe, rail, and truck. ii. Raw material is stored on-site in tanks. iii. Production of some raw materials is on-site. Plant 1 i. The plant makes the same material for Products 1 and 2. ii. Cycle time is 12 days. EMGT 6500 iii. No changeover time is required. iv. Process reliability is 90%. v. Yield is 95%. vi. First pass yield is 87%. vii. Shut down for 3 weeks every 18 months to refurbish the process. viii. Observed inventory: A. 5 days of hydrogen cyanide (HCN) (in tank). B. 0 days of propane (in pipe). C. 30 days of platinum (catalyst). Plant 1 Shipning i. Products 1 and 2 are shipped out by barge and rail to Plant 2(83%) and to customers (17%) by rail and truck. ii. Products 1 and 2 are stored on-site in tanks before shipment. Plant2 Receiving i. Products 1 and 2 are shipped in by barge and rail. ii. Products 1 and 2 are stored on-site in tanks before use. Plant 2 i. The plant makes the same material for both Products 1 and 2. ii. Cycle time is 30 days. iii. Two hour changeover time is required. iv. Process reliability is 82%. v. Yield is 85%. vi. First pass yield is 68%. vii. Shut down for 2 weeks every 24 months to refurbish the process. viii. Observed inventory: A. 25 days of Product 1 (in tank). B. 12 days of Product 2 (in tank). C. 30 days of mixture 3Z4 (in tank). EMGT 6500 i. Products 1 and 2 are shipped out by rail and truck. ii. Products 1 and 2 are stored on-site in tanks before shipment. Plant 3 Receiving i. Products 1 and 2 are shipped in by rail and truck. ii. Products 1 and 2 are stored on-site in tanks before use. iii. Observed inventory: A. 35 days of Product 1 (in tank). B. 32 days of Product 2 (in tank). Plant 3 i. The plant makes a different item for both Products 1 and 2. ii. Cycle time is 30 days. iii. Eight hour changeover time is required. iv. Process reliability is 72%. v. Yield is 75%. vi. First pass yield is 62%. vii. Shut down for 3 weeks every 18 months to refurbish the process. viii. Observed inventory: A. 35 days of Product 1 (in warehouse). B. 32 days of Product 2 (in warehouse). Plant 3 Shipning i. Products 1 and 2 are shipped out by rail and truck. ii. Products 1 and 2 are stored on-site in warehouses before shipment