Engitek.com

All  Engineering and Technology Information in One Place.....

Home

About This Site

Sections  Directory

Search This Site

Privacy Policy

For Discussion of These Topics + Visit  the New Engitek Science and Technology Forum

 

Tired of looking for a job?, Cansado de buscar trabajo?

 

Semiconductors Devices

 

Electronics Technology Information Sites

 

Science and Tech Forum

 

Electronics Engineering Information by Categories

 

Engineering and Science Software

 

Free Science-Tek Magazines and Publications

 

Regulatory Offices and Agencies and Standards

 

Patents  Information

 

Prototypes Developing Houses, Devices and Tools

 

IC’s Foundries  and IC Development Services

 

Certification Labs

 

Operation Manuals

 

Physics Units Converter Calculators

Convert any type of unit into any other of any system or scale

 

Alternative Energies Tutorials:

Biofuels

Ocean Energy

Wind Energy

Solar Energy

Geothermal

 

Lean Manufacturing Tutorials:

The Seven Causes of Waste

The 5S

The 5 Why’s

The 4 M’s +1

Cause Effect / Fish Diagram  

The 4W’s +H+W

DMAIC

FMEA

Project Charter Example

Value Stream Mapping Introduction and Icons

Current or Present State Map

Future Sate Mapping

Cell Production

Kanban Production System

 

EarthquakesTutorials

 

Electronics and Electromechanical Distributors

 

Jobs Portal

Easily find your dream Job

 

Technology News

 

Science News

 

Business News

 

Electronics, RF and Communication Concepts

Rsistors and capacitors colors code

The Logarithm

The bel, decibel , the dbm and the dbmv

Electrical noise definition and Thermal noise

Signal to noise ratio

CONTENT

Lowest Prices for Solar Cells

Best Solar Energy Books

Lowest price Solar Panels

Wind Turbines and Parts

Best Wind Energy Books

Search this site

Para nuestros amigos de habla hispana, los invitamos a visitar el portal tecnológico en español:

www.industriaytecnologia.com

 

Current or Present State Map

 

<< continue from previous page

 

The following example shows the way to outline a present or current sate map, to understand this section you must first read the previous page.  

Example of a Simple Present State Mapping of a Process of Five Steps, in a real life situation the current state map will be much more complex than this simple example, however even the most complex one can be developed understanding this basic concept.  

Value Stream Mapping, Current State Map

Note that it could exist a FIFO line between any operation but for sake of simplification will be omitted by now. Also note that there is a serious capacity excess on the forming operation.

 

Days of Inventory at Hand:

The inventory on hand in each operation is calculated by dividing the daily shipping quantity by the parts inventory.

 

Example:

How many days of inventory on hand is at the cutting operation station?

Daily shipping = 200 units per day

Parts inventory at cutting station = 1000

Inventory at hand for the cutting operation = 1000/200 = 5 days

 

Also the materials days inventory can be calculated for each particular station to know process bottle necks.

Example process capacity Vs inventory rate:

How many days of inventory is for the operation “cutting”

The CT= 50 Sec

Available time= 27,600

Up Time = 27,600 X 0.95 = 26220 Sec

Units per day capacity= (26220/50) = 524.4

Parts inventory= 1000 parts

Inventory to process at station “cutting” = (1000/524.4) = 1.9 days, we can perform the same calculations for all other operations.

 

Basic Attributes Definitions:

CT= Cycle Time: The time that takes to complete a given operation or process

CO= Changeover Time: The time that takes to change a tooling, prepare a production line, cell or a production unit for a new run.

 

Avail= Availability Time: Is the available working time available in one shift minus programmed brakes such as lunch time and resting brakes, normally given in seconds.

Example For the Cutting Operation:

If a working shift has 8.5 hour = 8.5X 60 =  510 minutes minus 0.5 hours lunch = 510 - 30 = 480 minutes  minus two resting brakes of 10 minutes each will be 480 - 20 = 460 minutes or 27600 Seconds of available time

 

UT= Uptime %= (Availability-CO)/(Availability) all converted to seconds.

Example:

Considering a given tooling changeover time of 20 minutes, then the available uptime for the example will be:

 

UT= (460 - 20)/460 = 0.95 or 95%

 

 

Continue Future State Mapping  Part One >>

Production

Control

Daily or Weekly Production Plan

Supplier

Customer

Cutting

Forming

Painting

Assembly

Packing

CT=50Sec

CO= 20 min

Avail= 27,600

1

1

1

Uptime = 95%

Daily

Daily

Daily

Daily

Daily

Monthly Forecast

+ Weekly Orders

Monthly Forecast

+ Weekly Orders

I

1000

Daily Shipping

200 units

I

800

I

700

I

900

I

950

I

 950

CT=20 Sec

CO= 0 min

Avail=27,600

Uptime = 100%

CT=50Sec

CT=20 Sec

 CT= 40 Sec

 CO= 0 min

 Avail= 27,600

 Up time = 100%

CT=40 Sec

 CT= 45 Sec

 CO = 5 min

Avail= 27,600

 Up time = 96.7%

CT=45 Sec

 CT= 40 Sec

 CO= 0 Min

 Avail= 27,600

 Up time = 100%

 CT=40 Sec

5 days

4 days

3.5 days

4.5 days

4.7 days


Statistics  Summary
Total Value Stream Process = 21.7 days
Total Cycle Time= 195 seconds

4.7 days

Capacity =524
Capacity =1380
Capacity =690
Capacity =593
Capacity =690
Basic Considerations
Shift Duration = 8.5 hours
Lunch Time = 0.5

Production

Supervisor

    Shipping 950    Warehouse