Question: I need to come up with a future state value stream map and improvement plan. I have the current state and info about the scenario.

I need to come up with a future state value stream map and improvement plan. I have the current state and info about the scenario. I think need a future state map and to know how to make an improvement plan. Can someone please help?

Scenario:

Your factory makes a product with a daily demand of 1730 units. The factory works three 8-hour shifts per day, and works 7 days a week. There is no downtime within the process, as operators stagger breaks and shift changes so that the process never stops running. Despite the great uptime performance, your factory struggles to meet your customer demand, and you find yourself in a constant state of backorder with some workers forced to work significant overtime.

Your product is produced in 4 steps, and has an overall lead time of 48 hours. Your team has performed a GEMBA walk to determine the source of your issues. The following observations were recorded for each of the steps in your current state process:

Prep Raw Material

C/T: 20 seconds/part

Inventory: 500 parts

Number of operators/shift: 2

Machining

C/T: 45 seconds/part

Number of Machines: 3

Number of operators/shift: 3

Inventory: 10 parts

Inspecting

C/T: 120 seconds/part

Number of operators/shift: 1

Inventory: 200 parts

20% overtime at this step

Clean and Package

Cleaning C/T: 40 seconds/part

Packaging C/T: 40 seconds/part

Number of operators/shift: 1

Inventory: 0 parts

10% overtime at this step

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