Question: Value Stream Mapping Case: TWI Industries: Steering Arm Product data Part name: Steering arm metal arm with forged fittings welded to each end. Variants: 20
Value Stream Mapping
Case: TWI Industries: Steering Arm
Product data
Part name: Steering arm metal arm with forged fittings welded to each end.
Variants: 20 lengths X 2 dia. X (3 types of ends on one side + 3 types of ends on other side) = 240.
Customer requirement
24000 pieces per month.
Order size: 25-200, with an average of 50 pieces.
Corrugated box packaging with up to 5 steering arms in a box.
Several daily shipments per day by truck to various customers.
Production time availability
20 days in a month.
2 shift operation in all processes.
8 hours every shift. Overtime if necessary.
Two 15-minute breaks during each shift.
Manual process stops during the breaks.
Unpaid lunch.
Demand planning and production control section
Make-to-order business.
Current manufacturing lead time 27 days.
Lead time quoted to customer 60 days.
Customers insist for order adjustment 2 weeks before shipment, leading to order expediting.
Batching of orders to minimize changeovers.
Process information
Process sequence: Cutting the rod Machining the end fittings Welding the end fittings to the rod Deflash Painting Assembly
- Cutting (Shared facility)
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 forgings (Dedicated facility)
Automatic machining process with one machine attendant.
Cycle time: 30 seconds.
Changeover time: 2 hours.
Reliability: 100%.
Observed inventory: 24 days of raw forging from supplier. 4 days of machined forgings.
- Welding workstation 1 (Dedicated facility)
Welds the first machined forging to the rod.
Automatic process, with operator load and unload external to 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.
- Welding workstation 2 (Dedicated facility)
Welds the second machined forging to the rod.
Automatic process, with operator load and unload external to 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 facility)
Automatic process, with operator load and unload external to machine cycle.
Cycle time: Operator 10 seconds. Machine 30 seconds.
Changeover time: 15 minutes for length and 1 hour for diameter.
Reliability 100%.
Observed inventory: 5 days for welded arms.
- Painting
Steering arms are shipped to outside vendor for painting.
Painting lead time: 2 days.
One daily truck pickup of unpainted arms and drop-off of painted arms.
Observed inventory: 2 days at the vendor. 6 days of painted arms at TWI.
- End-fitting assembly (Dedicated facility)
Manual process with six operators.
Total work time per piece: 195 seconds.
Changeover time: 10 minutes.
Reliability: 100%
Observed inventory: 4 days of finished steering arms.
- Shipping department
Removes parts from finished goods warehouses and prepares for truck shipment.
Q. Prepare Value Stream Map (VSM)
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