Current and Future State Value Stream Map in Machining. Before: Batch process, high Final Inspection rejects, 32% scrap costs Future: Continuous Flow, all operations start up and Run at the same time, each machine feeds back to each other in real time any issues. All issues are detected through in-process inspection and using Internal Customer (next machining centre) as the ultimate check and balance. COST TO IMPLEMENT = ZERO $$

1. CURRENT STATE VSM –8 Operators, OEE= 52%
Customer Complaint
Total Cycle Time = 14 days
Value Added Time = 7 min
2 people
C/T = 2 min
C/O = 3 hr
Uptime = 71%
Inspection
2 people
Milling
C/T = 4 min
C/O = 2 hr
Uptime = 64%
2 people
C/T = 10 min
C/O = 4 hr
Uptime = 28%
CNC 2
2 QC
Late Delivery
5 min1 min1 min
5 days 1 day2 days 3 days
Production
Order
WK
D
Wk
6 WEEKS INVENTORY
DELIVERED EVERY
SHIPMENT TO SAVE
ON TRANSPORTATION
COSTS C/T = 12 min
C/O = 30 min
Uptime = 83%
CNC 1
3 days
0
Customer
BSupplier
1
Supplier
2
3 weeks
lead time
WIP WIP
VA Time
NVA Time
I
33% SCRAP

2. 3x Week
Market Forecast
Lead Time = 4 days
Value Added Time = 14 min
Customer
A
Customer
B
1 people
C/T = 2 min
C/O = 20 min
Uptime = 88%
Inspection
2 people
Milling
C/T = 4 min
C/O = 0.5 hr
Uptime = 78%
1 people
C/T = 3 min
C/O = 30 min
Uptime = 67%
CNC 2
1 people
Shipping
Production
Control
Supplier
1
Supplier
2
C/T = 2 min
C/O = 30 min
Uptime = 93%
CNC 1
D
I
3 min2 min2 min
1 days 1 days1 days1 day
2 min
INVENTORY TURN-
OVER RATE
NVA Time
VA Time
1 Piece Flow and continuous feedback loop
9 % SCRAP