Draw a value stream map

Manage the Dot Company. Your Model A product (shown as Figure 1) is very popular. Recently high demand for this product has put your production process under pressure, and it is not performing well. You decide to try Lean Production methods. You gathered the following information about the process:

• Forecasts come in from your customer via email monthly. Orders come in from your customer via email weekly. Currently demand is 750 Model A pages per day. You distribute schedules to the production process daily via paper production schedules. You ship to your customer once per day.
• You send forecasts to your paper and colored dot supplier via email monthly, and send orders via email weekly. The supplier ships paper and colored dots to you Mondays and Wednesdays.
• Paper and colored dots from your supplier go into your warehouse. Currently there are 4,500 pages of paper in the raw material warehouse. To simplify this Kaizen event, we are going to focus only on the paper and focus on the colored dots raw material inventory in a future Kaizen event.

The order of the processes is Raw Material Storage and Paper Clipping (paper clip five pages together), Green Dot Work Station, Orange Dot Work Station, Yellow Dot Work Station, Red Dot Work Station, Blue Dot Work Station, Inspection, and Paper Unclipping and Shipping. You have measured the cycle time of each of the processes, and found that each dot takes three seconds to process, so for example the Yellow Dot Work Station has a cycle time of nine seconds. The cycle time of the paper clipping process is five seconds. Each process has an Uptime of 100%. There is no change-over time since the operations do not change over. The cycle time for the inspection step is five seconds. You operate one shift of ten hours per day. You operate weekdays.

You measure the WIP between the work stations. The count after each station is: 3,000 pages after Raw Material Storage/Paper Clipping, 1,875 pages after Green, 1,125 pages after Orange, 0 pages after Yellow, 750 pages after Red, 0 pages after Blue, and 563 pages after Paper Unclipping/Shipping. The Finished Goods Inventory is currently 375 pages.

You measure the yield of each work station. The yield measures are: Paper Clipping 100%, Green 100%, Orange 98%, Yellow 80%, Red 95%, Blue 95%, and Paper Unclipping 100%.