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Lean Value Stream Mapping Project

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Lean Value Stream Mapping Project

  1. 1. Project Phase 1 Value stream mapping of Pilot plant by Schawan Kunupakaphun Srividya Sharvankumar Rushi Patel
  2. 2. Content What is Pilot Plant? Process Flow for Pilot Plant External and Internal customer Requirements Work time Process information Value Stream Mapping Area of improvement
  3. 3. Pilot Plant Trial for a New Product ● Pilot plant runs trial for various compound that are developed in an R&D ● The compound is tested for the feasibility of its commercial production ● Provides sample of the product to the expected customers for them to test the product in their facility. ● On time delivery of samples to the customer is critical. As the sample will let the customer to provide us the commercial scale production order if the material passes their specifications. ● pilot plant aims at testing the process within the existing facility available at the pilot plant ● The value stream for the pilot run in this project is related to a single product
  4. 4. Process Flow for Pilot Trial ● Upon the arrival of the order for a sample production following are the series of event followed: ● Decide the operation philosophy for the process. ● Execute the modifications. ● Checking of the changes ● Information to operating team ● Conduct the run ● Data compilation ● Product packaging ● Discussion on findings of batch with the design team ● Dispatch of material to customer ● Two suppliers involved:- Process chemical supplier( supplier 1) and Starting Mat. supplier(Supplier 2) ● Lead time for obtaining both material is two weeks by 2 shipment every week.
  5. 5. External Customer Requirements ● 50kg of pyrazole acid per month ● Specification for the final product is provided to the production control team. ● Customer order to produce 150 kg within 3 months. ● 3kg material in PTFE cans ● Weekly shipment ● Pharmaceutical company requires orders to come 30 days before shipment. Internal Customer Requirements ● Weekly updates regarding the product dispatch ● Weekly progress from the production team about the new findings and issues in the operation. ● Weekly process data collected in all the operations during all the shifts.
  6. 6. Work Time ● 330 days per year ● Three shifts in all production department. ● 8.5 hrs every shift with 30 mins break during each shift. ● Manual process stops during breaks. ● 30mins of lapover time between each shift.
  7. 7. Process Information - Reaction ● Batch process with 2 operators per shift. ● Number of shifts: 3 ● Cycle time : 8hrs ● Changeover Time : 4hrs ● Changeover Frequency : 2 per day ● Observed Inventory: o 10 days of unreacted raw materials o 1 day of reacted material. ● Uptime: 67% ● Yield : 100%
  8. 8. Process Information - Filtration ● Batch process with 1 operators per shift. ● Number of Shifts: 3 ● Cycle time : 10hrs ● Changeover Time : 3hrs ● Changeover Frequency : 2 per day ● Observed Inventory: o 4 days of filtered material. ● Uptime: 83% ● Yield : 90%
  9. 9. Process Information - Distillation ● Batch process with 2 operators per shift. ● Number of shifts : 3 ● Cycle time : 12hrs ● Changeover Time : 12hrs ● Changeover Frequency : 1 per day ● Observed Inventory: o 1 day of final product ● Uptime: 50% ● Yield : 98%
  10. 10. Process Information - Packaging ● Manual process with 1 operators per shift. ● Number of Shifts: 1 ● Cycle time : 3hrs ● Changeover Time : 1hr ● Changeover Frequency : 2 per day ● Observed Inventory: o 7 days of packed product ● Uptime: 75%
  11. 11. Value Stream Mapping Pilot plant Customer 2 Engineering Design 30 days2 weeks Supplier 2 (Catalyst and starting materials) Supplier 1 (Process Chemicals) Receiving I 10 days Production Control 1 day C/T = 8 hr C/O = 4 hr CoF = 2/day Upt = 67% Yield = 100% Shift = 3 Reaction (O) 2 I 1days C/T = 10 hr C/O = 3 hr CoF = 2/day Upt = 83% Yield = 90% Shift = 3 Filtration (O) 1 I 10hrs I 1 day C/T = 3hr C/O = 1 hr Upt = 75% Shift = 1 Packaging (O) 1 2* week Production Supervisor Weekly 12hrs 3hrs 8hrs 10 days 1 days 4 days 1 days 7 days Total LT = 23days Total VA time = 33hrs Weekly updates Engineering design 1 day Modification 7 days 50 Kg/mo PTFE Can = 3kg Product Dispatch I 7 days4 days Weekly Progress Customer 1 Daily Schedule Checking Modification 2 days C/T = 12 hr C/O = 12 hr CoF = 1/day Upt = 50% Yield = 98% Shift = 3 Distillation (O) 2
  12. 12. Takt Time Total available working hours in a month = 27.5 * 24 = 660 hrs Total Quantity to be produced per month = 50 kg Takt Time = Time Available/ Qty Required = 660/50 = 13.2 hrs/kg Overall Cycle time => 33hrs to produce 3 kg = 11 hrs/ Kg Hence the overall cycle time for the process < Takt time
  13. 13. (O) 2 C/T = 12 hr C/O = 12 hr CoF = 1/day Upt = 50% Yield = 98% Shift = 3 Value Stream Mapping Pilot plant Customer 2 Engineering Design 30 days2 weeks Supplier 2 (Catalyst and starting materials) Supplier 1 (Process Chemicals) Receiving I 10 days Production Control 1 day C/T = 8 hr C/O = 4 hr CoF = 2/day Upt = 67% Yield = 100% Shift = 3 Reaction I 1days C/T = 10 hr C/O = 3 hr CoF = 2/day Upt = 83% Yield = 90% Shift = 3 Filtration (O) 1 I 10hrs I 1 day C/T = 3hr C/O = 1 hr Upt = 75% Shift = 1 Packaging (O) 1 2* week Production Supervisor Weekly 12hrs 3hrs 8hrs 10 days 1 days 4 days 1 days 7 days Total LT = 23days Total VA time = 33hrs Engineering design 1 day 50 Kg/mo PTFE Can = 3kg Product Dispatch I 7 days4 days Customer 1 Daily Schedule Checking Modification 2 days Distillation (O) 2
  14. 14. Area of improvement ● The raw material stays in the warehouse for 10 days before the process is started which needs to be reduced. ● There is holdover for all the intermediate material with the intermediate after filtration to be as high as 4 days. ● The finished product stays in the warehouse for 7 days before the customer pulls it. ● Product stays in inventory for 7 days therefore no.of shift is high. ● Staffing for the reaction and distillation has high number of operator. ● The uptime is very low for the reaction and distillation steps. ● The changeover time is high for all the processes.
  15. 15. Thank You

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