VSM Exercise

Case:
ABC Gamma company gets monthly order of 10,080 pieces of components from XYZ
Kingkong Inc in the form of monthly forecast and weekly schedules received through the
access of customer’s website. The components are delivered to the customer in cartons
containing 42 pieces per carton. On receipt of forecast and schedule, production control
department communicates to supplier their monthly forecast and weekly orders through e-
mail. They also prepare weekly production plan in format no. FR-PPC-003/1 and send to
production supervisor. The production supervisor prepares daily operation plan and hands
them over to the all the operation, inspection and packaging in-charges with an instruction
to perform all operations in a batch of 1000. The raw component supplier delivers the
components every week through public transport system. The company works in single
shift of eight hours (excluding lunch break) and 6 days a week. The company’s
management allows 2 tea breaks of 10 minutes each during the shift.
The VSM teem collected the following data:
Raw Hon. Final Bond
Mat M/c comp Comp Deburr. insp. room
Week1 2368 4800 3836 1942 2007 1988
Inventory

Week2 2604 5323 3361 2078 2000 1995

Week3 2512 5088 3456 1987 1990 2023
Week4 2517 4948 3348 1992 2003 1995
Machining Honing Deburring Inspect Packaging
Week1 6 0.6 11 0 0.35
Downtime

Week2 6.6 0.4 8.5 0.7 0.6

Week3 5.3 0.43 9 1 0.2
(Hrs)

Week4 7 0.49 9.8 0.25 0.8

Machining Honing Deburring Inspect Packaging

Week1 68 6 0 5 5
Week2 55 5 0 5 5
Ch-over

Week3 56 4 0 5 5
(mts)
time

Week4 61 5 0 5 5

Operators 1 1 0 1 1
CT (Sec) 44 40 5 30 10
 VSM Exercise
Process Flow Chart: