QUESTION:

EXPLANATION:

(There are 21 operations on the flow chart, only the most important operations will be translated into the value stream map. The black squares on the flow represent each activity the present state is going through. There are 8 different types of waste. Suggest what type of waste is involved with each step in the process. The suggestions should represent the future state on the value stream map)

TOOLS:

3. Based on the below data for the present state and future state, for the crank shaft production line, draw the value stream map that depicts the present state. Highlight points on your map that indicate the "type of waste." Sequence of operations - Operation No. 3 Work center Manual 02 03 04 05 06 07 9 11 12 13 14 15 16 17 18 5 5 5 5 5 4 Operation description Initial inspection Both end rough boring and recentering Semi-finish turning of flange outer diameter Other journal finish grinding Thrust journal finish grinding Pin finish grinding Gear end and flange end tapping and drilling Flange end finish boring Levd inspection Flange end finish grinding Gear end finish grinding Magnetic (non-destructive) insption Keyway milling Dynamic balancing O holes polish and webs debut Super-finishing of journals, pin and thrust face End inspection Gear end and flange outer diameter lapping and polish Ol hole washing and scial punching Final washing Audit inspection 08 Manual 0-10 0-11 0.12 0-13 0-14 Manual 0-16 Manul 0-18 Manual 0-20 Manual Machine type Manual CNC machine Lathe machine Grinding machine Grinding machine Grinding machine Drilling machine Lathe machine Manual Grinding machine Grinding machine Magnetic field Milling machine Balancing machine Manual Super finishing machine Roller block Lathe machine Manual Washing machine Roller block 19 20 21 Present Future Savings 15 36 1 11 5 275.69 147.94 OFDPE Process Flow Chart 1: Present State Activity Work: Manufacturing of the crankshaft Operation Transport Method: Present Future Delay D Inspection Storage 0 Distance (m) Time (min.) Dista Time Operation Dce (min) Material input 75 Loading the crank on inspection table 1.5 Gauge inspection 2.55 Both end rough boring and re-centering on Mic 0-2 20.47 Crank movement to Mic 0-3 2.4 Semi-finish turning of flange outer diameter on Mic Manual 0-3 Loading the crank on track 1 Crank travel on track 10 Crank movement to Mic 0-4 2.7 Other journal finish grinding on MC0-4 13 Crank movement to inspection table 1 Gauge inspection Loading the crank on track 1 Crank travel on track 3 Crank movement to Mic 0-5 1 Thrust journal finish grinding on Mic 0-5 8.5 Crank movement to inspection table 1 Gauge inspection Storage on pallet for next operation Pallet movement to Mc 0-6 Pin finish grinding on Mic 0-6 21.7 Crank movement to inspection table 2 Gauge inspection Loading the crank on track 1 Crank travel on track 5 19 2.4 14.2 2 25 1.5 1 15 ID Manual 34.5 L 6.52 0 0 32.69 6.1 . 3.9 7.6 I lol Crank movement to M'c0-7 Gear and flange end tapping and drilling on MIC 0-7 Crank movement to inspection table Gauge inspection Loading the crank on track Crank travel on track Crank movement to Mic 0-8 Flange end finish boring on Mic 0-8 Gauge inspection Storage on pallet for next operation Pallet movement to Mic 0-10 Flange end finish grinding on Mic 0-10 Gauge inspection Storage on pallet for next operation Pallet movement to Mc 0-11 Gear end finish grinding on Mic 0-11 Crank movement to Mc 0-12 Magnetic (non-destructive) testing on Mic 0-12 Crank movement to Mic 0-13 Keyway milling on M/C 0-13 Gauge inspection Loading the crank on track Crank travel on track Crank movement to Mic 0-14 Dynamic balancing on Mc 0-14 Loading the crank on debur table Oil holes polish and webs deburt Loading the crank on track Crank travel on track Crank movement to Mic 0-16 Super-finishing of Jr. pin and thrust face on Mico- 16 Loading the crank on inspection table End inspection Lapping and Polish on lathe machine Loading the crank on track Crank travel on track Crank movement to Mic 0-20 Final washing on Mic 0-20 Crank movement to inspection table Audit inspection Storage on pallet for next operation Forklifts required for crank movement Loading the crank on track for final packaging TOTAL 1 7 9.6 1 4 1 1 2 1 DDD 19.3 3.5 1 3.5 1 DO 4.5 U 1 2 Manual Manual 1 59 275.6 9 147.94 my Customer Supplier Process Box Inventory Transportation Kaizen Kaizen Burst Material flow Manual Information Electronic Information 3. Based on the below data for the present state and future state, for the crank shaft production line, draw the value stream map that depicts the present state. Highlight points on your map that indicate the "type of waste." Sequence of operations - Operation No. 3 Work center Manual 02 03 04 05 06 07 9 11 12 13 14 15 16 17 18 5 5 5 5 5 4 Operation description Initial inspection Both end rough boring and recentering Semi-finish turning of flange outer diameter Other journal finish grinding Thrust journal finish grinding Pin finish grinding Gear end and flange end tapping and drilling Flange end finish boring Levd inspection Flange end finish grinding Gear end finish grinding Magnetic (non-destructive) insption Keyway milling Dynamic balancing O holes polish and webs debut Super-finishing of journals, pin and thrust face End inspection Gear end and flange outer diameter lapping and polish Ol hole washing and scial punching Final washing Audit inspection 08 Manual 0-10 0-11 0.12 0-13 0-14 Manual 0-16 Manul 0-18 Manual 0-20 Manual Machine type Manual CNC machine Lathe machine Grinding machine Grinding machine Grinding machine Drilling machine Lathe machine Manual Grinding machine Grinding machine Magnetic field Milling machine Balancing machine Manual Super finishing machine Roller block Lathe machine Manual Washing machine Roller block 19 20 21 Present Future Savings 15 36 1 11 5 275.69 147.94 OFDPE Process Flow Chart 1: Present State Activity Work: Manufacturing of the crankshaft Operation Transport Method: Present Future Delay D Inspection Storage 0 Distance (m) Time (min.) Dista Time Operation Dce (min) Material input 75 Loading the crank on inspection table 1.5 Gauge inspection 2.55 Both end rough boring and re-centering on Mic 0-2 20.47 Crank movement to Mic 0-3 2.4 Semi-finish turning of flange outer diameter on Mic Manual 0-3 Loading the crank on track 1 Crank travel on track 10 Crank movement to Mic 0-4 2.7 Other journal finish grinding on MC0-4 13 Crank movement to inspection table 1 Gauge inspection Loading the crank on track 1 Crank travel on track 3 Crank movement to Mic 0-5 1 Thrust journal finish grinding on Mic 0-5 8.5 Crank movement to inspection table 1 Gauge inspection Storage on pallet for next operation Pallet movement to Mc 0-6 Pin finish grinding on Mic 0-6 21.7 Crank movement to inspection table 2 Gauge inspection Loading the crank on track 1 Crank travel on track 5 19 2.4 14.2 2 25 1.5 1 15 ID Manual 34.5 L 6.52 0 0 32.69 6.1 . 3.9 7.6 I lol Crank movement to M'c0-7 Gear and flange end tapping and drilling on MIC 0-7 Crank movement to inspection table Gauge inspection Loading the crank on track Crank travel on track Crank movement to Mic 0-8 Flange end finish boring on Mic 0-8 Gauge inspection Storage on pallet for next operation Pallet movement to Mic 0-10 Flange end finish grinding on Mic 0-10 Gauge inspection Storage on pallet for next operation Pallet movement to Mc 0-11 Gear end finish grinding on Mic 0-11 Crank movement to Mc 0-12 Magnetic (non-destructive) testing on Mic 0-12 Crank movement to Mic 0-13 Keyway milling on M/C 0-13 Gauge inspection Loading the crank on track Crank travel on track Crank movement to Mic 0-14 Dynamic balancing on Mc 0-14 Loading the crank on debur table Oil holes polish and webs deburt Loading the crank on track Crank travel on track Crank movement to Mic 0-16 Super-finishing of Jr. pin and thrust face on Mico- 16 Loading the crank on inspection table End inspection Lapping and Polish on lathe machine Loading the crank on track Crank travel on track Crank movement to Mic 0-20 Final washing on Mic 0-20 Crank movement to inspection table Audit inspection Storage on pallet for next operation Forklifts required for crank movement Loading the crank on track for final packaging TOTAL 1 7 9.6 1 4 1 1 2 1 DDD 19.3 3.5 1 3.5 1 DO 4.5 U 1 2 Manual Manual 1 59 275.6 9 147.94 my Customer Supplier Process Box Inventory Transportation Kaizen Kaizen Burst Material flow Manual Information Electronic Information