Quick Manufacturing Stencil

Transcription

1 Quick Manufacturing Stencil Quick Manufacturing is one of evsm s Quick Stencils and supports plant level mapping of discrete parts and assemblies in industries like automotive, electro-mechanical, and medical equipment. It provides easy, fast, and focused mapping as shown below: Quick Manufacturing is actuy a compatible set of 3 stencils as shown below. Sketch Sketch: Simple sketch shapes, no data blocks Fast Easy C/T C/O LT Lite Pro Standard Variables Lite: Pro: Design Macro Shapes + data blocks + equations + charts ideal for most maps + cost, space, energy concepts that increase map leverage. Quick stencils are popular because of their capability and also because of the excellent deployment materials available. These include example maps, publications, and learning options. x mapping speed and quantified improvements with a well designed set of icons, variables, macro shapes, equations, and charts. F(x) Equations The technical concepts addressed by the Quick Manufacturing stencil are shown below. Focused -Cycle -Multiple Stations -Qty Per Cycle -Takt -Utilization OEE Capacity -Transfer Lot Size Cycle / Takt Chart -Scrap -Changeover -Setup -Rework -Performance -Availability Effective Capacity Chart Map Hierarchy -Map Linkage Space Utilization -Side Calculations -Shared - Utilization - Bottlenecks Quick Manufacturing - Allocation Balance Chart Energy Efficiency s Lead Multi-Path Maps -Critical Path -VA & NVA -Queues and Delays -Process Lead Lead Chart - Holding -Activity Based -Material Chart An example map drawn in Quick Mfg is shown overleaf. evsm

2 9 3 Rolls BQSI Buckland Quality Surgical Instruments A Activity Lead Tower Hills Foundry A3 A. From Supplier Casting Sets Yr Rolls 8 A3 Fornost Quality Steelworks Activity Lead A Machine Cycle Qty Per Cycle OEE Percent 7 Stations 3 Stn 3 A A From Supplier.7 8 Machined Kits 9 3 Yr A Spring Steel Rolls A6 Polish Cycle 3 Qty Per Cycle OEE Percent 9 3 A7 Machine and form caliper springs Cycle 7 Qty Per Cycle OEE Percent 7 A7 7. Final Parts 6 A8 A Springs Value 7. K Value 6 K Assemble Cycle 3.7 Qty Per Cycle OEE Percent 8 Scrap Percent 3.7 A9 Cutters DATE FILENAME REVISED 6/9/3 BQSI_MAP.VSD A TITLE DESCRIPTION 6/9/3 Built with evsm Quick Mfg Stencil Package and Ship Cycle Qty Per Cycle Value K Value K 7 Value K. Value K Value K 3 Control Activity Cycle / Takt Chart.6 OEE Percent 9 Activity. A M33B Surgical Bone Cutters Boxes 7 Current State Z.36 A A To Distributor Summary Total Value Takt Chetwood Medical Supplies Customer Lead 6.3 Value Percent Z. Summary Total Value Takt.7 8. Lead.9 Value Percent.3 Z3 / W Map Capture Capture w maps easily and quickly using the Sketcher components Kaizen Kaizen bursts can be applied, detailed and prioritized towards a future state value stream Shared s Shared activities can be modeled by adjusting demand or available time OEE Measures Activities comprehend OEE, downtime, scrap, etc Multi-Lane Maps Filter charts and summaries by path numbers to handle multi-lane maps by Customer Record demand for one or more customers Activity Based Support for cumulative cost calculation Lean Metrics Calculates Lead, Takt, & VA s line Automaticy build and calculate the timeline Automaticy plot Capacity and Lead charts Quick Manufacturing Example Map with Features Need more frequent deliveries Bottleneck due to downstream scrap Assembly damaging polished surface 8 6 A7 A A6 A8 A 3 Unpredictable availability Activity Takt Cycle Per Scrap Loss OEE Remainder Loss DownStr Loss. Legend. Summary Total Value 8. K

3 Quick Transactional Stencil Quick Transactional is one of evsm s Quick Stencils and supports transactional value streams and includes concepts of divergent flow, shared resources across activities, resource balancing charts, and activity based costing. It provides easy, fast, and focused mapping as shown below: Quick Transactional is actuy a compatible set of stencils as shown below. Fast Easy C/T C/O LT Sketch Pro Standard Variables Sketch: Pro: Design Macro Shapes Simple sketch shapes, no data blocks + additional concepts that increase map leverage. Quick stencils are popular because of their capability and also because of the excellent deployment materials available. These include example maps, publications, and learning options. x mapping speed and quantified improvements with a well designed set of icons, variables, macro shapes, equations, and charts. F(x) Equations The technical concepts addressed by the Quick Transactional stencil are shown below. Divergent Flows Iterative Processes -Number of Iterations Lead -Process -Delay -Process NVA - Linking activities Focused -Decision Points -Automated demand calculation Query Handling Quick Transactional Swim Lane Mapping -Horizontal Swim Lanes -Vertical Swim Lanes -Departmental Views -Query - Per Query s -Activity based cost - cost - Utilization - capacity - usage and balancing An example map drawn in Quick Transactional is shown overleaf. evsm

4 A Customer Input Input Output Output A Queue Queue. 7 Usage Chart Escalated Support A3 PT PT NVA Query PT Review and Support Requests Process Delay Activity Output A9 A7 Hotline Staff Quantity RQ 8 Effeciency Decision Utilization 3. Output PT PT NVA Query PT A8 Level Staff Quantity RQ A Escalated Support Process 8 Effeciency 3.3 Activity Output 9 3 PT PT NVA Query PT Delay Query Delay Query Process Utilization Query Percent 6 3 Output Z A A6 Summary Total Lead Output Output.7 Output to Customer. Output to Customer. Total VA 7. Total NVA Total Services Lead / Escalated Support Review and Support Requests Review and Support Requests A7 Escalated Support Escalated Support Escalated Support A8 Effective Query Usage Usage VA Legend Hotline Staff Level Staff Linkage between high level and detailed maps Support for activity overlap Hide/show data capability to simplify maps for printing and communication Explicit support for query, interactions, and C&A (Complete and Accurate) concepts Support for dedicated and shared resource pools balance charts and FTC calculation Automatic charts for lead time, capacity, and cost Critical path support and summary calculation for each value stream path Support for multiple lanes, multiple outcomes Decision-based routing with percentage input for each route Automated demand calculation at each activity based on routing percentage Quick Transactional Example Map with Features

5 Quick Enterprise Stencil Quick Enterprise is one of evsm s Quick Stencils and supports enterprise level value stream mapping of supply chains and logistics. It provides easy, fast, and focused mapping as shown below: Quick Enterprise is actuy a compatible set of 3 stencils as shown below. Sketch Sketch: Simple sketch shapes, no data blocks Fast Easy C/T C/O LT Lite Pro Standard Variables Lite: Pro: Design Macro Shapes + data blocks + equations + charts ideal for most maps + additional concepts that increase map leverage. Quick stencils are popular because of their capability and also because of the excellent deployment materials available. These include example maps, publications, and learning options. x mapping speed and quantified improvements with a well designed set of icons, variables, macro shapes, equations, and charts. F(x) Equations The technical concepts addressed by the Quick Enterprise stencil are shown below. Focused -Right Qty -Right Product -Right Place -Right -Right Quality Order Execution -Shutdown -Reduce -Partnership -Purchase volume -Criticality score -Strategic Product Supplier Criticality Quality -First -Defective Defects Chart Quick Enterprise Lead -Lead s by Path Lead Chart -Raw Material -WIP -Finished Goods Carrying - of Capital - Damages -Insurance on inventory - Obsolescence - Shrinkage - - -Batch Qty -Distance -Volume ation Capacity -Plant -Warehouse - Holding -Conversion - Customer -Material -Warehouse -Delivered - -Complaints An example map drawn in Quick Enterprise is shown overleaf. evsm

6 RM C WIP C FG 3 C Linking Maps Connectivity between Enterprise maps and Plant level maps Rolling calculation of first time correct. Lean Metrics Lead, Processing, and Travel metrics Info & Material Flow Information flow and material flow mapping at Enterprise Level annual carry cost calculation Carry Lead Calculations + Plots Lead calculation and charting for multiple paths in the supply chain C Defective Defective C C Defective Defective Defective C A Processing A3 AST Plant First Batch Qty Distance A Processing. Atlas Steel Components C C RM C WIP C FG 6 C Mile C Defective 3 First 6. A First Distance Lead Chart 7 6. C Mile A6 ATLAS Warehouse Processing First Control Activity 9.9 Weekly C A7 First Distance C 6 8 A AST Plant A3 A Atlas Steel Components 3.9 Control Activity A C C Mile A6 ATLAS Warehouse A7 A8 Scissors Assembly A8 Scissors Assembly Processing 3 RM 3 C WIP C FG 3 C 7. C Defective First.86 Legend Processing A9 First Distance A Customer A C C Mile Process 8 Summary Lead 3.9 C Total Processing 9. C Total 6. C Total Distance 3. Mile First Quick Enterprise Example Map with Features At a glance, inventory visualization throughout Enterprise Visualization

7 Quick Processing Stencil Quick Processing is one of evsm s Quick Stencils and supports plant level mapping of chemicals or food processing. It combines speed, ease of use, and power as shown below: Fast Easy Quick Processing is actuy a compatible set of stencils as shown below. C/T C/O LT Sketch Pro Standard Variables Sketch: Pro: Design Macro Shapes Simple sketch shapes, no data blocks + additional concepts that increase map leverage. Quick stencils are popular because of their capability and also because of the excellent deployment materials available. These include example maps, publications, and learning options. x mapping speed and quantified improvements with a well designed set of icons, variables, macro shapes, equations, and charts. F(x) Equations The technical concepts addressed by the Quick Processing stencil are shown below. -Step Yield -Cycle -Multiple Stations Capacity -Qty Per Cycle Cycle / Takt Chart -Products -By-product -Co-product Lead -VA & NVA -Queues and Delays -Process Lead Lead Chart Focused -Giveaway -Downtime -Scrap -Changeover OEE Quick Processing Multi- Path Maps -Setup -Sanitization -Availability Capacity Loss Chart -Shared - Utilization - Bottlenecks - Allocation Balance Chart s - Holding -Activity Based -Material Chart An example map drawn in Quick Processing is shown overleaf. evsm

8 Co-Products Value streams can include two or more co-products Weight Balance Sequence arrows and a weight balance calculation connects customer demand(s) to required production in local quantities at any activity Local Quantities Separation Quantities at each activity can be measured in local units most easily*** Output from an activity can be multiple materials by weight percent Merge Ingredients can be merged by weight percent Step Yield Activities have a step yield measure to balance input and output weights Byproducts Byproducts from the value stream can be mapped in addition A Muggle Factory Supplier Lead Comp. Supplier Requirement A3 Supplier Lead Comp. Supplier Requirement 98.9 Various A = Bin Weight Per Comp. Requirement s of 3. A = Bin Weight Per Comp. Requirement s of Gelatin LO Q LO Q 7 6 Cycle / Takt Chart / Quick Processing Example Map with Features DIW DIW DIW DIW 7 A Make Slurry (Local Output) = Weight Per Cycle Process Lead 6. Step Yield. DIW DIW DIW A6 A7 Stamp beans (Local Output) = Weight Per Cycle Process Lead Step Yield Box Packaging (Local Output) = Case Weight Per Cycle Process Lead 6 Step Yield. Scrap A8 = Case Weight Per Comp. Requirement s of.7 DIW FG 7..7 A9 LO Q 3 = Case Weight Per Qty Distance s of Supply DIW Num Week Mile A A6 A7 Effective Output Cycle Activity Output Takt Scrap Loss EOCR A Legend Weight Per A Takt shop Distributors = Case Summary Total Lead Total Value Value Percent

9 Quick Healthcare Stencil Quick Healthcare is one of evsm s Quick Stencils and supports value stream mapping for healthcare. It includes concepts of divergent flow, shared resources across activities, resource balancing charts, and activity based costing. It provides easy, fast, and focused mapping as shown below: Quick Healthcare is actuy a compatible set of stencils as shown below. Fast Easy C/T C/O LT Sketch Pro Sketch: Pro: Simple sketch shapes, no data blocks + additional concepts that increase map leverage. Quick stencils are popular because of their capability and also because of the excellent deployment materials available. These include example maps, publications, and learning options. x mapping speed and quantified improvements with a well designed set of icons, variables, macro shapes, equations, and charts. Standard Variables Design Macro Shapes F(x) Equations The technical concepts addressed by the Quick Healthcare stencil are shown below. Divergent Flows Iterative Processes -Number of Iterations Lead -Process -Delay -Queues and Wait - Linking activities Focused -Decision Points -Automated demand calculation Query Handling Quick Healthcare Swim Lane Mapping -Horizontal/Vertical Cross-functional - by department - by department -Activity based cost - cost -Query - Per Query s - utilization - capacity - usage and balancing Quality -Percentage Complete & Accurate -C&A by Activity and -C&A by Pathway An example map drawn in Quick Healthcare is shown overleaf. evsm

10 Support for activity overlap Wait Hide/show data capability to simplify maps for printing and communication Explicit support for query, interactions, and C&A (Complete and Accurate) concepts Efficiency Critical path support and summary calculation for each value stream path Support for dedicated and shared resource pools balance charts and FTC calculation Automatic charts for lead time, capacity, and cost Queue Decision-based routing with percentage input for each route Wait Support for multiple lanes, multiple outcomes Efficiency Automated demand calculation at each activity based on routing percentage Quick Healthcare Example Map with Features Output Z Incoming Patients Incoming A 9. Output Triage Wait 9 9 A Process PT Triage 9. Delay.. Output A3 Output Admit or Fast Track A9 3 PT Output Quantity 7 RQ RN Utilization A Admit Queue 3.33 A6 Fast Track Wait. PT Output Output PT A8 A Process Admission 7. Delay A7 Quantity RQ MD Process 63. Fast Track Treatment Delay Utilization 9... Output Output Z Patient Admitted Outgoing 7. Patient Discharged Z3 Outgoing 63. Z Summary Total Lead. Total VA 3. Total NVA Total Services Lead Z Summary Total Lead.73 Total VA 6. Total NVA Total Services Lead.73.