CREATING A CURRENT STATE MAP

DIRECTIONS: Make sure you use a blank sheet of paper and draw this current state map out using a pencil. Draw the map .

The customer, General Motors Company (GMC), is requesting a batch of side mirrors be delivered by truck every two hours from the company you are making this value stream map for (Michigan Mirror Monopoly). GMC requires a total of 960 mirrors a day (480 left side and 480 right side). There is only one shift working at all of the plants. The mirrors are entirely made of ABS plastic resin which comes from DuPont Chemical. Two tons of ABS resin is shipped by train twice a day from DuPont. GMC 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 one operator. It takes 20 seconds and five pounds of ABS to produce a mirror. It takes 10 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 8 full hours of work time. Lunches and breaks are separate and make for a 9 hour work day. Figure out the access inventory between each process by calculating the cycle time for an 8 hour work day with no defects or scrap. 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 change over 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 30 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. Please make a timeline of the mirror making operation. Only make a map of what is given from what you have learned to date.