Question: Prepare the value stream map (VSM) using the data given below Product dates Part Name: Steering Arm - Metal arm with forged hardware welded to
Prepare the value stream map (VSM) using the data given below
Product dates
Part Name: Steering Arm - Metal arm with forged hardware welded to each end.
Variants: 20 lengths X 2 dia. X (3 types of spikes on one side + 3 types of spikes on the other side) = 240.
Customer requirement
24000 pieces per month.
Order size: 25-200, with an average of 50 pieces.
Packed in a corrugated cardboard box with up to 5 steering arms in a box.
Several daily shipments per day by truck to various clients.
Availability of production time
20 days in a month.
2-shift operation in all processes.
8 hours each shift. Extra hours if necessary.
Two 15-minute breaks in each shift.
The manual process stops during breaks.
Unpaid lunch.
Demand planning and production control section
Custom business.
Current manufacturing time 27 days.
Delivery time quoted to the client 60 days.
Customers insist on order adjustment 2 weeks prior to shipment, leading to expedited order.
Order batches to minimize changeovers.
Process information
Process sequence: Cutting the rod – Machining the end fittings – Welding the end fittings to the rod – Deburring – Painting – Assembly
- Court (shared installation)
Manual process with 1 operator.
Cycle time: 15 seconds.
Changeover time: 15 minutes for length and 1 hour for diameter.
Reliability: 100%.
Observed inventory: 20 days of uncut rods. 5 days of cut rods.
- Machining of forged parts (Dedicated facility)
Automatic machining process with a machine assistant.
Cycle time: 30 seconds.
Change time: 2 hours.
Reliability: 100%.
Observed Inventory: 24 days raw forging from supplier. 4 days of mechanized forging.
- Soldering work station 1 (dedicated installation)
Welds the first machined forging to the rod.
Automatic process, with a loading and unloading operator external to the machine cycle.
Cycle time: Operator 10 seconds. Machine 30 seconds.
Changeover time: 15 minutes for length and 1 hour for diameter.
Reliability 90%.
Observed inventory: 3 days for welded arms.
- Soldering Workstation 2 (dedicated installation)
Weld the second machined forging to the rod.
Automatic process, with a loading and unloading operator external to the machine cycle.
Cycle time: Operator 10 seconds. Machine 30 seconds.
Changeover time: 15 minutes for length and 1 hour for diameter.
Reliability 80%.
Observed inventory: 3 days for welded arms.
- Deflash Workstation (Dedicated Installation)
Automatic process, with a loading and unloading operator external to the machine cycle.
Cycle time: Operator 10 seconds. Machine 30 seconds.
Changeover time: 15 minutes for length and 1 hour for diameter.
100% reliability.
Observed inventory: 5 days for welded arms.
- Chart
Track arms are sent to a third party supplier for painting.
Painting execution time: 2 days.
A daily collection truck for unpainted arms and delivery of painted arms.
Observed inventory: 2 days at the seller. 6 days of painted arms in TWI.
- Mounting of final accessories (dedicated installation)
Manual process with six operators.
Total working time per piece: 195 seconds.
Change time: 10 minutes.
Reliability: 100%
Observed inventory: 4 days of completed steering arms.
- shipping department
Withdraws parts from finished goods warehouses and prepares for shipment by truck.
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