lean manufacturing

Draw a value stream map for a product that goes through two major operations. The company making this product is XYZ Inc. and the supplier of their major raw material is ABC Inc. The customer Global Inc., requires the product on a daily basis at the rate of 900 units. XYZ works 1 shift of 8.5 hours, 30 minutes of unpaid lunch and with two breaks of 15 minutes each. The two processes are blanking and machining The blanking operation uses an automatic saw operated by one person, and has an uptime of 80% and cycle time of 0.5 minutes per blank produced. ABC supplies raw material on a weekly basis for 4500 units resulting in an average inventory of 2250 units at the blanking operation. The machining operation has a cycle time of 1 minute and produces two pieces at a time. This is a semi-automatic machine with manual loading and unloading done by one operator. The uptime of the machine is 90%. It has been observed that to decouple the two processes there is a buffer inventory of 1800 blanked units in the machining department. XYZ prefers to maintain a finished inventory of about 2700 products in its warehouse. Global sends weekly orders to XYZ through electronic means, whereas XYZ gives monthly requirements to ABC. XYZ production control office gives weekly requirements to the production supervisor who in turn gives the daily production requirements to the two departments