TWIINDUSTRIESVALUESTREAMMAPPINGASSIGNMENT

FindingsfromCurrentStateMapping

TWIcurrentlytakescustomerorder27daystogetthroughTWIsproductionprocesses,butactualit
takes72daysbecausemorehiddeninventoryfoundinthesystem.

Thecustomerisforcedtoplacetheorderinadvance(TentativeSchedule60days),duetolonglead
timeinservicingtheorder.Thecustomernotabletoprovidetheexactdimensionin60days,dueto
thisweareforcedtokeepbufferstock(Steelrods&forging)toservethecustomerspecific
requirementwhichareprovided2wkspriortoshipping.

SupplierslikeMichigansteelcompanytakingleadtimeof16wksforsteelrodsandIndianaCastings
takes12wkstosupplytherawforging.ThismakestheTWImorecomplicatedandtheyareinsistingfor
60daysschedulefromthecustomer.

Weobservethemajorbottlenecktomeetingcustomerrequirementistheinventorybuildupineach
process.Althoughthetotalprocessingtimes57,960sec,inthis57,600secisspentinpaintingcarried
outbythethirdparty.

Thereforeouraimistoreducelessthan14dayswhichwillfacilitatethecustomertoprovidecorrect
dimensionofthematerial,whichwouldtherebyreduceourrawmaterialinventory

ImprovementsinFutureStateMapping

Weldingstation1&2hascycletime40seconds(IncludingOperatorandMachine),forgingisthefeeder
forboththestationandittakes30seconds.Thereisanecessasitytosynchronisetheforgingprocess
from30secondsto20seconds,sothatitwillfeedboththeweldstationwithoutanystoppage.

Loadlevellinginforgingfrom30to20sectofeedbothWS1&WS2(Kaizentobedone)

Kaizenburstisnecessaryintheassemblyareatoreducethecycletimefrom198sec.

Manpowerreducedfrom5to4intheassemblycellthroloadlevelling

No.oftripsincreasedfrom2to6tripspermonthforsteelrodsandrawforgings

Bystreamliningandintegratingthepaintingthesubcontractingoperation,withinourlean
manufacturingsystem,usingsupermarketbeforeandafterthepaintingoperation.

InventoryTurnover

Rod Rod
WS1 Forging Machined WS2 Deflashing Painting End
Total
VSM
Cutting
Forge
Assembly Lead
(In
Time
Days)
Before 20 5
3
20
4
3
7
6
4
72
After

10

LoadLevelling
OperationTimeinsec
45
40
35
30
25
20
15
10
5
0
Cutting

Welding1

Forging

Welding2

Deflashing

Before
165seconds5operators

33seconds/operator

41.25seconds/operator

After
165seconds4operators

Total
Inventory
Turnover
3.33

24.0