" C U RR ENT STATE"

Suppliers - Trident - Reliant - Metal West - Others

As Ordered

ISheer Turret Deburr Brakes Assy &

H ardwarePain t Ship /

Packag ingFG I

I I I I I I1 3 11 7 6 6 7

Day Shift On lyCapacity a t Turretdete rmines when toSheer

C /T = 3 0 M i n

30 D a ysR a w S to c k 5 D a y s

Shifts: 2 + W eekend1 Person can operate2 machines

Hi-Flex Capability

40-50% P roductivity

C/O = 45-60 Min

Capacity: 1 job/hr(~10 p lanks/job)

C /T = 1 05 M in

1 4+ D a y s

Shifts: 2 + W eekend

C / T = 12 0 M in

KAIZENDeburr is aBottleneck

2 D a ys

S hifts: 2 + W eekend

S etup : 10-120 Min

40-50% Productivity

98-99% Yie ld (buffersused to make up forscrap)

Up time is High - PM'sscheduled on W /E

C /T = 1 2 0 M in

14 D ay s

KAIZENS e tu p R e d u c ti o n s

Hardware: 2 shifts / 3 peopleAssembly: 1 shifts / 3 people

C / T = 6 0 M i n

P a i n t.5 D a y s

C l e an3 - 5 D ay s

C / T = 1 D a y1 D a y

KAIZENIm p le m e n t P h o s p h a te

D ip C le a n S ys tem

KAIZENIn cre a se C a p a c i t y X 3 a t

p a i n t b o o t h , p o w d e rp a in t, a n d b a tch o v e n

1 Shift Operation

Dedicated to BusRoute from 5:30am toNoon

No ProductivityMeasu re

C /T = 1 D a y

KAIZEND e d i c a te d S t ag i n g

A re a s

I2 -5 D a y s

2X Month

Inspection

Dallas

3X W eekM ,W ,F

OSP

1I

2 D ays

Inspection

95% First Pass Yie ld

Production LeadTime

72 Days

Processing Time2days7hrs25min

30 Days 5 Days 14 Days 2 Days 14 Days 5 Days 2 Days

30 min 105 min 120 min 120 min 60 min 1 day 1 day

ProductionControl

Purchase Orders

Placed as needed based upon:* Gross inventory check for spot buys* Bus-Route(contract) forecast

M anufacturing OrdersShop Schedule

Issues Daily Prior ities

O SPPlating

2 Prima ry & 2Seconda ry Suppliers

A p pliedM ateria ls

Daily

FO RECAST

Value Stream MapS ta nd ard P ro duc t Fam ily( 75% of Pro du ct)2/15/2000

Supplier XYZ

Value Stream Mapping - An example of Lean Tools -

" FUTUR E STATE"

Suppliers - T rident - Reliant - Metal West - O thers

A s O rdered

Sheer Turret De burr Brakes Assy &H ardw are

Paint Ship /Packaging

1 3 11 7 6 6 7

Day Shift O nlyCapacity at Turretdete rm ines when toSheer

C / T = 3 0 M i n

30 D a y sR a w S to c k

Shifts: 2 + W eekend1 Person can ope ra te2 m achines

Hi-Flex Capability

40-50% Productivity

C/O = 45-60 Min

Capacity: 1 job/hr(~10 p lanks/job)

C /T = 1 0 5 M in

Shifts: 2 + W eekend

C /T = 1 2 0 M i n

Shifts: 2 + W eekend

Setup: 10-120 Min

40 -50% Productivity

98 -99% Yie ld (buffersused to make up forscrap)

Uptime is H igh - PM'sscheduled on W /E

C / T = 12 0 M in

Hardware: 2 shifts / 3 peop leA ssembly: 1 shifts / 3 peop le

C / T = 6 0 M in

C / T = 1 D ay1 Sh ift Operation

Ded icated to BusRou te from 5:30am toNoon

No ProductivityMeasure

C /T = 1 D a y

I2 - 5 D ay s

3X / Week

Inspection

Dallas

3X W eekM,W ,F

Production LeadTime

33 Days

Processing Time2days7hrs25min

30 Days .5 Days .5 Days .5 Days .5 Days .5 Days .5 D ays

30 min 105 min 120 min 120 min 60 min 1 day 1 day

ProductionControl

Purchase O rders

Orders are launched atcalculated re-order points forRaw G ood Kanbans

M anufacturing Orders

Based on F in ished GoodsReplenishment Triggers &

Spot Buy Orders

Shop Schedule

Issues Daily Prior ities

O SPPlating

2 Prim ary & 2S econdary Supp liers

A ppliedM ateria ls

Daily

Value Stream M apS ta n dard P ro du ct F am ily( 75% o f P rod uc t)2/25 /2000

Supplier XYZ

?.5 D a y s .5 D a y s .5 D ay s .5 D a ys . 5 D a ys . 5 D a y s

?Inventory Sizing of Da llas provided gas

panel enc losu res & gas panel piecepa rts (gas panel parts & spa res )

? ? D a y s

S h o p o rd ers ar e L o ad L e ve led b a s e do n P r o d u c t F am il y S ch ed u lin g R u le s

OSP

1

In spection

95% First Pass Yie ld

Finished GoodsInventory

FORECAST

Daily Pull Orders

O rders are launched atcalculated re-order points forFin ished Good Kanbans

Daily Orders - EDI Pull

Value Stream Mapping - An example of Lean Tools -