Production Control

coil

Stamping

Changeover

Weld +ASSY

Daily

Coils

Daily Order

2020

20

EPE = 1 Shift

C/O <10 min.

Take = 58.6 sec.

C/O = 0

Uptime = 100%

2 Shifts

total worktime = 165 sec.

weld changeover

welderuptime

elimwaste

CustomerMetallservice

Daily

2 days165 sec1 day1 sec1,5 days

L

R

C/0 = Changeover Time; EPE = every part every-; Take (time) = Rate of customer demand

6-week Forecast

Daily Order Daily Order

Market Forecast

coil

Staging

Shipping

tote 2020

Information flows

Lead time lagger

Material flows

Production Control

Weekly order Monthly order

Process A

C/T = 300 sec

C/O = 60 min

Uptime = 80%

2 Shifts

27000 sec available

Process B Process C

1202 733 593C/T = 45 sec

C/O = 10 min

Uptime = 90%

2 Shifts

27000 sec available

C/T = 300 sec

C/O = 240 min

Uptime = 100%

2 Shifts

27000 sec available

MonthlyWeekly

1783

Supplier Customer

Shipping

6 days 300 sec 4 days 45 sec 1 day 240 sec 3 days

Production lead time = 14 days

Processing time = 585 sec

Production ControlCentral production scheduling or control department, person or operation.

Customer/SupplierIt is the usual starting point for material flow

Inventories

Shipment

Electronic Information FlowElectronic flow such as EDI, Internet, intranets, LANs, WANs

Information Flow

Material Flow/ PUSH Arrow"Pushing" of Material from One Process to the Next Process

Manual InfoPull ArrowPull movement between internal steps.

Supermarket

Safety Stock

Material Pull

Dedicated ProcessProcess, operation, machine or department, through which material flows

Process with Data

Shared Process

Data BoxThis icon goes under other icons that have significant data required for analyzing and observing the system

Truck shipment/LogisticsShipment using external transport

Forklift Truck

Plane

Ship

FIFO LineFirst-In-First-Out sequence flow.

Supermarket Parts

Workcell

Kaizen Burst

Operator

Production Kanban

Material Withdrawal Kanban

Signal Kanban

Kanban Post

Sequenced Pull

Load Levelling

MRP/ERPScheduling using MRP/ERP or other centralized systems.

Go-SeeGathering of information through visual means.

Timeline

Timeline Total

Process

Process

Process

MAX=XX

Time Time

Time

Other Information

Value Stream Map Example

Assembly & InspectionPaintingWeldingMilling

Metallservice

ProductionControl

Annual Production Plan Market Forecast Customer

C/T = 2 min

C/O = 60 min

Uptime = 74%

C/T = 5 min

C/O = 45 min

Uptime = 70%

C/T = 7 min

C/O = 40 min

Uptime = 55%

C/T = 3 min

C/O = 35 min

Uptime = 95%

Week

ly Sc

hedule

Note: C/T = Cycle Time; C/0 = Changeover Time

Daily

Sch

edul

e Daily Schedule

Daily Schedule

Weekly

Delivery

Schedule

5 days 2 min 10 days 5 min 12 days 7 min 8 days 2min 30 days

Total Lead Time = 65 Days

Value Added Time= 17 min

Weekly Daily

5 Days 30 Days

Recieving Shipping

2 2 3 3