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03 - Current State Map - Acme

The document presents a current state map of a manufacturing process. It consists of five views: 1) an overview of production quantities and shifts, 2) addition of processes, inventory, and data, 3) showing material flow between processes, 4) inclusion of information and material flows, 5) completion with lead times and data. The map models the end-to-end process of receiving coils from a steel supplier to final assembly and shipping of products over 2 shifts daily.

Uploaded by

Omar Abu-obialla
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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116 views6 pages

03 - Current State Map - Acme

The document presents a current state map of a manufacturing process. It consists of five views: 1) an overview of production quantities and shifts, 2) addition of processes, inventory, and data, 3) showing material flow between processes, 4) inclusion of information and material flows, 5) completion with lead times and data. The map models the end-to-end process of receiving coils from a steel supplier to final assembly and shipping of products over 2 shifts daily.

Uploaded by

Omar Abu-obialla
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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First View of the Current State Map Showing the

Customer
State Street
Assembly

18,400 pcs/mo
- 12,000 L
- 6,400 R
Tray = 20 pieces
2 Shifts
Second View of the Current State Map with all the
Processes, Data Boxes and Inventory Triangles
State Street
Assembly

18,400 pcs/mo
- 12,000 L
- 6,400 R
Tray = 20 pieces
2 Shifts

STAMPING S. WELD #1 S. WELD #2 ASSEMBLY #1 ASSEMBLY #2 SHIPPING


I I I I I I
Coils 200 T 4600 L 1100 L 1600 L 1200 L 2700 L Staging
5 days 1 2400 R 1 600 R 1 850 R 1 640 R 1 1440 R

C/T = 1 second C/T = 39seconds C/T = 46seconds C/T = 62seconds C/T = 40seconds
C/O = 1 hour C/O = 10 minutes C/O = 10 minutes C/O = 0 C/O = 0
Uptime = 85% Uptime = 100% Uptime = 80% Uptime = 100% Uptime = 100%
27,600 sec avail 2 shifts 2 shifts 2 shifts 2 shifts
EPA = 2 weeks 27,600 sec avail 27,600 sec avail 27,600 sec avail 27,600 sec avail
Third View of the Current State Map showing the
Material Flow
Michigan State Street
Steel Co. Assembly

500 ft coils 18,400 pcs/mo


- 12,000 L
- 6,400 R
Tray = 20 pieces
2 Shifts

Tues +
Thur
1x
Daily

STAMPING S. WELD #1 S. WELD #2 ASSEMBLY #1 ASSEMBLY #2 SHIPPING


I I I I I I
Coils 200 T 4600 L 1100 L 1600 L 1200 L 2700 L Staging
5 days 1 2400 R 1 600 R 1 850 R 1 640 R 1 1440 R

C/T = 1 second C/T = 39seconds C/T = 46seconds C/T = 62seconds C/T = 40seconds
C/O = 1 hour C/O = 10 minutes C/O = 10 minutes C/O = 0 C/O = 0
Uptime = 85% Uptime = 100% Uptime = 80% Uptime = 100% Uptime = 100%
27,600 sec avail 2 shifts 2 shifts 2 shifts 2 shifts
EPA = 2 weeks 27,600 sec avail 27,600 sec avail 27,600 sec avail 27,600 sec avail
Fourth View of the Current State Map with
Information Flows and Push Arrows
6 week
PRODUCTION
forecasts CONTROL
30/60/90 day
forecasts
Michigan State Street
Weekly fax
Steel Co. MRP
Daily Order Assembly

500 ft coils 18,400 pcs/mo


- 12,000 L
Weekly Schedule - 6,400 R
Tray = 20 pieces
2 Shifts

Daily Ship
Schedule

Tues +
Thur
1x
Daily

STAMPING S. WELD #1 S. WELD #2 ASSEMBLY #1 ASSEMBLY #2 SHIPPING


I I I I I I
Coils 200 T 4600 L 1100 L 1600 L 1200 L 2700 L Staging
5 days 1 2400 R 1 600 R 1 850 R 1 640 R 1 1440 R

C/T = 1 second C/T = 39seconds C/T = 46seconds C/T = 62seconds C/T = 40seconds
C/O = 1 hour C/O = 10 minutes C/O = 10 minutes C/O = 0 C/O = 0
Uptime = 85% Uptime = 100% Uptime = 80% Uptime = 100% Uptime = 100%
27,600 sec avail 2 shifts 2 shifts 2 shifts 2 shifts
EPA = 2 weeks 27,600 sec avail 27,600 sec avail 27,600 sec avail 27,600 sec avail
Completed Current State Map with Lead-Time Bars
and Data
6 week
PRODUCTION
forecasts CONTROL
30/60/90 day
forecasts
Michigan State Street
Weekly fax
Steel Co. MRP
Daily Order Assembly

500 ft coils 18,400 pcs/mo


- 12,000 L
Weekly Schedule - 6,400 R
Tray = 20 pieces
2 Shifts

Daily Ship
Schedule

Tues +
Thur
1x
Daily

STAMPING S. WELD #1 S. WELD #2 ASSEMBLY #1 ASSEMBLY #2 SHIPPING


I I I I I I
Coils 200 T 4600 L 1100 L 1600 L 1200 L 2700 L Staging
5 days 1 2400 R 1 600 R 1 850 R 1 640 R 1 1440 R

C/T = 1 second C/T = 39seconds C/T = 46seconds C/T = 62seconds C/T = 40seconds
C/O = 1 hour C/O = 10 minutes C/O = 10 minutes C/O = 0 C/O = 0
Uptime = 85% Uptime = 100% Uptime = 80% Uptime = 100% Uptime = 100%
27,600 sec avail 2 shifts 2 shifts 2 shifts 2 shifts
EPA = 2 weeks 27,600 sec avail 27,600 sec avail 27,600 sec avail 27,600 sec avail

Production=23.6 days
5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days Lead Time
Processing=188 secs
1 second 39 seconds 46 seconds 62 seconds 40 seconds Time
Completed Current State Map with Lead-Time Bars
and Data
6 week
PRODUCTION
forecasts CONTROL
30/60/90 day
forecasts
Michigan State Street
Weekly fax
Steel Co. MRP
Daily Order Assembly

500 ft coils 18,400 pcs/mo


- 12,000 L
Weekly Schedule - 6,400 R
Tray = 20 pieces
2 Shifts

Daily Ship
Schedule

Tues +
Thur
1x
Daily

STAMPING S. WELD #1 S. WELD #2 ASSEMBLY #1 ASSEMBLY #2 SHIPPING


I I I I I I
Coils 200 T 4600 L 1100 L 1600 L 1200 L 2700 L Staging
5 days 1 2400 R 1 600 R 1 850 R 1 640 R 1 1440 R

C/T = 1 second C/T = 39seconds C/T = 46seconds C/T = 62seconds C/T = 40seconds
C/O = 1 hour C/O = 10 minutes C/O = 10 minutes C/O = 0 C/O = 0
Uptime = 85% Uptime = 100% Uptime = 80% Uptime = 100% Uptime = 100%
27,600 sec avail 2 shifts 2 shifts 2 shifts 2 shifts
EPA = 2 weeks 27,600 sec avail 27,600 sec avail 27,600 sec avail 27,600 sec avail

Production=23.6 days
5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days Lead Time
Processing= 188 Secs
1 second 39 seconds 46 seconds 62 seconds 40 seconds Time

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