Improving Mixed Model Value Streams

Transcription

3 Lean, VSM, & evsm 3 Working with Quick Stencils in evsm v8 0 Plant Level Mapping 3 Discrete Parts VSM Terms 30 ACME Case Study Plant 36 Quick Manufacturing Tutorial 49 Mixed Model Environment 5 Mixed Model Slides 6 Hand Exercises 6 ACME Mixed Model Case Study 8 ACME Case Study Plant 8 evsm Wizards 87 Spaghetti Wizard Tutorial 89 Standard Work Wizard Tutorial 05 Copyright 05 The evsm Group, All Rights Reserved

6 U - shape Layout for Assembly Cell Replace D 4 Drilling Station Milling Area 4 A 00 ATLAS Warehouse Activity Lead 0 A 030 Wk 5 5 S New lighting in Hanger 50 Replace D 7 Drilling Station Group Value Stream Mapping Event. 07 Blanks 7500 A 040 Mold Handles Sec Daily Order A Molded Blanks 3850 A Control Activity Sharpen 45 5 Activity 0 Stations Stn Sec A Drilled Blanks 300 Lead Summary A 030 Blanks. 06 A 050 Molded Blanks A 070 Drilled Blanks ly Order A 080 Assemble 0 60 Legend Sec Non Value Added Value Added A 090 Scissors A Customer Demand Z 00 Customer Takt 7000 all Summary Lead. 07 Total Value. Added Value Added 0. 3 Percent 0. % evsm / Supporting Process Improvement Wall Map Capture 8 / Takt Chart 7 6 S e c / I t e m Activity Takt Per Unit 0 A 040 A 060 A 080 Improve Analyze Prioritize 5 Kaizen Impact Matrix Impact On Value Ease Of Implementation 4 Copyright 05 The evsm Group, All Rights Reserved

7 What is evsm? Best Practice Maps Applying the standard Company specific Best Practice Maps evsm Standardized mapping & analysis Use maps for calculations Application Specific Stencils Excel Integration Capture wall maps VSM Icons for Visio Collaborative Tools Group Diagramming Data Interaction Brown Paper & Post-Its Visio Excel Copyright 05 The evsm Group, All Rights Reserved Lean VSM & evsm 5

8 evsm Architecture Process Based Toolbar Manufacturing Enterprise Processing Transactional Healthcare EPEI Multi-station Facility time Kanban Quick Stencils Wizards Drag and Drop Core Sketcher (wall maps) Standard Variables Built-in Equations Kaizen Impact Multi-path Maps Production Units Built-in Charts Kaizen Risk Multi-level Maps Data Variation What-If Studies Kaizen Report Visio + Excel Integration (3 bit + 64 bit) Windows Support (3 bit + 64 bit) 6 Copyright 05 The evsm Group, All Rights Reserved

9 Manufacturing Concepts C/T C/O LT Standard Variables Design Macro Shapes F(x) Built-in Equations Built-in Charts The technical concepts addressed by the Quick Manufacturing stencil are shown below. - -Multiple Stations - -Takt -Utilization OEE -Transfer Lot Size / Takt Chart -Scrap -Changeover -up -Rework -Performance -Availability Effective Chart Map Hierarchy -Map Linkage Space Utilization -Side Calculations -Shared Resource -Resource Utilization -Resource Bottlenecks Quick Manufacturing -Resource Allocation Resource Balance Chart Energy Efficiency Resources Lead Multi-Path Maps -Critical Path -VA & NVA -Queues and Delays -Process Lead Lead Chart - Holding -Activity Based -Material -Resource Chart Copyright 05 The evsm Group, All Rights Reserved Lean VSM & evsm 7

10 What is Lean? Lean is a set of concepts, principles, and tools used to create and deliver the most value from the customer s perspective while consuming the fewest resources....lean Enterprise Institute Lean Principles Value is defined from the Customer s perspective Map the Value Stream Create flow & eliminate waste Create pull where flow is difficult Seek perfection 8 Copyright 05 The evsm Group, All Rights Reserved

11 Lean Means... Lower cost Less inventory Less space Shorter lead-time Fewer people The Lean Process Current State Future State Implementation Plan Improvements Implementation...Learning to See, LEI Copyright 05 The evsm Group, All Rights Reserved Lean VSM & evsm 9

12 What is a Value Stream? All steps, both Value Added and Non Value Added, required to complete a product or service from beginning to end What is a Value Stream Map? A simple tool that visually represents what s going on in a value stream 0 Copyright 05 The evsm Group, All Rights Reserved

13 What is a Value Stream Map? ACME Scissors Manufacturing Current State / Takt Chart A00 60 Sec Daily Daily Production Control MRP A050 A 070 A090 A0 A60 Mold Handles Sharpen Drill Assemble Forecast 30 s ly Order Cardboard Boxes Activity Takt Per Z 00 ATLAS Warehouse Customer Activity Lead Customer 7000 Daily Demand ly Schedule A00 A50 Between Between A050 A070 A090 A0 Mold Handles Sharpen Drill Assemble Z40 Summary Lead.64 A030 Type Associates 0.8 Staff A060 Blanks Associates. Staff A080 Sharp Blanks Associates 0.5 Staff A00 Drilled Blanks Associates Staff A0 Scissors Total Value 6.00 Added Value Added 0.7 Percent % Takt 0. Activity Per 8 Stations Stn Activity Daily 9000 Demand Z00 Summary Lead Total Value 4.50 Added Value Added 0.08 Percent % Takt 0. VSM Learning to See Copyright 05 The evsm Group, All Rights Reserved Lean VSM & evsm

14 Types of Waste Transportation Excess Over Processing Duplicate Entry Over Production Excess Motion Confusion Waiting Defects Knowledge Hiding the Waste Process Process Process Process Long ups Water Level = Amount Poor Housekeeping Mixed Materials Delay in Delivery Machine Breakdowns Rework Generating Defective Products Copyright 05 The evsm Group, All Rights Reserved

15 What is a LEAN Value Stream? Define value from the customer s perspective Map the value stream Create flow and eliminate waste Create pull where flow is difficult Seek perfection imize the LEAD TIME Adequate & Efficient CAPACITY imum COST for QUALITY Lead,, Defects Waiting Excess Excess Motion Transportation Over Production Lead Over Processing Copyright 05 The evsm Group, All Rights Reserved Lean VSM & evsm 3

16 What is evsm? Software Tool: -VSM, A3 Reports, Spaghetti Reports, Communication Circles -Analyze VSM Data -Manage Lean Transformation Built on Visio and Excel Based on Publications from Lean Enterprise Institute Lean Workbooks Process Level Plant Level Materials Office Services Multiple Plants Across Companies 4 Copyright 05 The evsm Group, All Rights Reserved

18 What is a Quick Stencil? Very fast way to map Drag, Drop & Enter Values mated Calculation & Charts Total =VA + NVA =(5+++5) + (0+45+5) =3+70 =83 s Sec/ Mold Handles / Takt Chart A040 Sharpen A060 Assemble Sec/ A / Takt Chart Activity Takt Changeover Loss Per Unit Mold Handles Legend A040 Sharpen A060 Assemble A080 Activity Takt DownStr Loss Scrap Loss Per Unit Legend Visualizing 6 Copyright 05 The evsm Group, All Rights Reserved

19 Losses Sec/ / Takt Chart / Takt Chart A040 A060 A080 Mold Handles Sharpen Assemble Activity Takt 7 Changeover Loss6 Per Unit 5 Sec/ Legend 4 Activity Takt 3 DownStr Loss Scrap Loss Per Unit 0 A040 A060 A080 Legend Mold Handles Sharpen Assemble Visualizing Lead Copyright 05 The evsm Group, All Rights Reserved Lean VSM & evsm 7

21 U-shape Layout for Assembly Cell Replace D4 Drilling Station Milling Area 5S New lighting in Hanger 50 Replace D7 Drilling Station Group Value Stream Mapping Event 4 A00 ATLAS Warehouse Activity Lead A030 Wk 5 0 Blanks A040 Mold Handles Activity Sec A050 Molded Blanks A060 Control Activity Sharpen Sec 0 Stations Stn Lead Summary Daily Order 45 A070 Drilled Blanks 0.44 ly Order A030 Blanks.06 A050 Molded Blanks A070 Drilled Blanks 300 A080 Assemble 60 0 Legend Non Value Added Value Added Sec A00 A090 Scissors Customer Demand Z00 Customer 7000 all Summary Lead Total Value Added Value Added Percent Takt % 3 4 Kaizen Impact Matrix Bottleneck process. Above takt time. 3 4 Supermarket and pull system Kaizen Impact Matrix 00 Single cell option for sharpen and drill. 5 Badly unbalanced line. Quality issues on goods reaching customer Impact On Value Ease Of Implementation Improvement Cycle Select Product Family Wall Sketch Capture Map Sustain improvements Future State becomes Current State Improvement cycle continues Sec/ / Takt Chart Activity Takt Per Unit 0 A040 A060 A080 Analyze and Visualize Plan & Implement Improvements Create Future State Prioritize Improvements Impact On Value I II Kaizen Impact Matrix III IV Brainstorm Improvements Difficulty Of Implementation 8 0 Copyright 05 The evsm Group, All Rights Reserved Lean VSM & evsm 9

22 Working with Quick Stencils in evsm v8 evsm Toolbar Quick Stencil Access each Quick Stencil using the Open button and a corresponding Sketch Stencil for initial map capture and layout will open as well Drag out the red icons FIRST 3 Use the Green icons to draw the Flow 4 Yellow icons represent optional Add-on calculations A0070 Process x.xx Glue 5 Add-ons must be glued under existing data shapes Activity x.xx 7 8 Summary calculations matic Charts 6 Blue values get calculated automatically 0 Copyright 05 The evsm Group, All Rights Reserved

23 Main Stencil A0080 Process x.xx 9 For variable name help, select any variable and use the rightmouse button menu Name Help for a description of the variable. Copyright 05 The evsm Group, All Rights Reserved Lean VSM & evsm

24 Quick Stencil Try This:. Go to a new page and use the Open command to access the Quick Mfg stencil.. Which icons from the stencil must be put on the map first? 3. How do you get quick help on the icons in the stencil? 4. Drag out an Activity Center from the stencil. How do you get a quick description of the Qty Per Cycle variable in the center? 5. What is the meaning of the blue value in the Activity Center? Copyright 05 The evsm Group, All Rights Reserved

26 Activity Available Available = Planned Production after breaks Plant Available = Default Available for all activities Activity : Overrides the Plant Available at an activity Facility Wizard: Allows off-page calculation of Available for different shift patterns Activity Sequence Sequence arrows to explicitly establish upstream/downstream connectivity Rolling scrap calculation based on connectivity calculation based on connectivity Value stream path generation for multi-lane maps based on connectivity 4 Copyright 05 The evsm Group, All Rights Reserved

27 OEE Overall Equipment Effectiveness Availability Quality -Changeover, unplanned downtime, setup -Scrap (and rolling scrap) Performance -Machine, material, or operator inefficiency Resource Modeling Resources (Manpower) are now modeled explicitly within the value stream map. Resources can be connected to multiple activities. Resource VA and NVA times can be captured to help identify improvement areas. Resource cost handling. Bottleneck resources are identified (Resource Utilization). Resource usage (balancing) chart. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 5

28 Carrying Based on Calculated using Activity Based ing Carry Factors - of Capital -Damage -Obsolescence -Shrinkage -Insurance Customer Demand Multiple Customers Path-based demand Demand override (Activity Demand or Demand %) -Production for other value streams -Product family routing -Rework situation 6 Copyright 05 The evsm Group, All Rights Reserved

29 Kaizen Report, Impact & Risk Kaizen burst for improvement opportunities Association of bursts with activities Improvement prioritization via impact, difficulty, and risk Charting with impact and risk matrices Kaizen reporting to spreadsheet Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 7

30 Modeling analysis in Quick Mfg requires consideration of both activity capacity and resource capacity. Let s see it works. Activity So let s say that an activity has: = 5 mins = Activity = 0 s/ OEE = 80% Number of Stations = Then Per Qty Per Cycle Number of Stations 5.5 / Activity Activity OEE Per / This capacity calculation assumes that a station has all of the resources it needs over its activity time period to process items within the cycle time stated. If this is a concern, then explicit resources can be modeled and a resource capacity calculation can be done in addition. 8 Copyright 05 The evsm Group, All Rights Reserved

31 Resource Let s say that for a particular resource used by an activity, (could be a person or a machine) it has the following characteristics: Resource Qty = Resource = 8 s/ Resource PT (Resource Process ) = 0 / then, Resource Resource Resource Qty Resource PT / So in this example, while the Activity (independent of Resource consideration) is 384 /, the resource would actually limit the capacity to 96 /. The Quick Mfg stencil reports both the Activity and the Resource associated with each resource used by the activity. It also handles the issue of shared resources between activities. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 9

32 Discrete Parts VSM Terms For a full glossary of lean terminology, we recommend the Lean Lexicon. The terminology described here is specific to discrete parts and assemblies and we propose that you use it to standardize your variables on these types of maps. Acronyms OEE Overall Equipment Effectiveness NVA Non-Value Added VA Value-Added VSM Value Stream Map WACT Weighted Average WIP Work In Process 30 Copyright 05 The evsm Group, All Rights Reserved

33 Facility Related Terms Plant Operating the facility is open and available for equipment operation. Planned Production Planned Shutdown Lunch, breaks, planned maintenance Operating Loss s Loss from unplanned downtime, setups, changeovers Net Operating Performance Loss Loss from machine wear, operator inefficiency, substandard material Fully Productive Quality Loss Product that does not meet quality standard Takt : interval of planned production time at which the value stream needs to produce an item to meet demand. Lead : The time it takes for an item to move between two designated points in the process. OEE Rate = Availabili ty Rate Quality Rate Performance Rate OEE Availability Rate = Operating time Planned production OEE Quality Rate = Fully productive time Net Operating OEE Performance Rate = Net Operating Operating Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 3

34 Activity Related Terms Process Lead Stations: Number of identical stations of an activity. Each additional station reduces the Per Unit. : The time interval between a set of items exiting an activity and the next set. : The number of items produced during one cycle at one station. Per Unit = Stations Activity : Planned Production specific to an activity. Station Station Qty Per Cycle Activity Takt : Takt specific to an activity. Value-Added : of those work elements that transform the product in a way that adds value for the customer. Non-Value Added : of those work elements that adds but no value to the product or service as seen by the customer. Uptime: The percent of Activity that is actually available for production work after unplanned downtime. Per Changeover: required to switch a station from producing one type of item to another. Process Lead : from when an item enter an activity to when it leaves the activity. 3 Copyright 05 The evsm Group, All Rights Reserved

35 Terms Added : Additional cost put into an item by an activity. This is an addition to cost of any explicit resources modeled on the map (see Resource Terms). : The total cost put into an item to get it to a particular point in the value stream. Carrying Terms of Capital: This is the annual interest rate associated with borrowing money to finance inventory. Damages: The percentage of inventory damaged each year. Insurance on : The annual insurance premium as a percent of the inventory value. Obsolescence: The percentage of inventory that becomes obsolete each year. Shrinkage: The percentage of inventory that is lost each year. Total Carrying Factors: The overall Carrying factors calculated from the detailed factors above. Total Annual Carry : This is the annual cost associated with carrying a value of inventory. It is calculated by multiplying the Value and the Total Carrying Factors. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 33

36 Resource Terms Efficiency: Efficiency rating for a resource to allow for auxiliary activities (walking, interruptions..) Effective Resource : Resource * Resource Qty * Efficiency NVA Utilization: Resource Used for Non Value Added Activity / Effective Resource Resource : of this resource to process an item Resource NVA : Resource cost for NVA activity per item Resource PT: Resource time to process an item Resource PT NVA: The NVA portion of the resource time to process an item Resource Quantity: Quantity of resource available Resource Query : Resource cost to service queries in a time period Resource Rate: rate for a resource Resource : Resource available time after subtracting planned breaks. Resource Usage: Total resource usage per period via this pipe Resource Usage NVA: The NVA portion of the Total resource usage per period via this pipe Resource Utilization: Total Spent / Effective Resource Resource VA : Resource cost for VA activity per item Total Resource : per time period for this resource Total Spent: Total time used of this resource VA Utilization: Used for Value Added Activity / Effective Resource 34 Copyright 05 The evsm Group, All Rights Reserved

38 ACME Case Study Plant Introduction You will be using this case study to create a value stream map on the wall. With your group, read through the information below then complete the exercises at the end. Background and Overview ACME, founded in 965, specializes in high-quality surgical instruments and has recently added surgical, re-usable, double-action cutters to its catalog, retailing at 90 per set. Each set consists of four cast pieces which are supplied by Tower Hills Foundry. At ACME, the castings are machined, polished, and sent to the final assembly line. The metal for the springs is supplied by Fornost Quality steelworks in steel rolls which are cut down into springs and assembled with the castings. One casting set and one spring set makes one final Surgical Cutter. Finally, the finished product is individually packaged for shipping. The assembled cutters are sent to packaging where they are individually boxed and then stored for shipping. 36 Copyright 05 The evsm Group, All Rights Reserved

39 Value Stream Walk To capture the current state value stream, you meet the plant supervisor in the finished goods shipping area on Monday afternoon. You learn that the plant line works shifts per day, 5 days a week. Each shift is 8 hours including a 30 min break and two 5 min breaks. Shipment quantity to customers is 500 surgical cutters per week. You had previously asked the supervisor to collect inventory and time metrics for the line. Here is the inventory summary. Incoming Casting Kits Machined Kits awaiting Polishing Polished Kits ready for Assembly Rolls of Spring Steel Spring sets ready for Assembly Cutters ready for packaging Boxes ready for shipping Totals Units 000 set 50 set 00 set 0 roll 50 set 5 set 000 item As you walk upstream to where the cutters are packed, you learn that Packaging has just one part-time (4 hours per day) operator. Packaging takes minutes and adds to cost per cutter set. The OEE for the packaging process is 95%. Next you arrive at the Assembly area which is manned by 4 operators. Assembly takes 7 minutes per set and adds 3 to the cost. The scrap rate here is 0% and the OEE is 80%. You follow the castings supply upstream to the Polishing area which is manned by 4 operators, takes 5 minutes, and adds per set. The OEE is 95%. The Machine shop has machines dedicated to the cutters and requires two operators on each. This operation adds per set, has a scrap rate and OEE of 0% and 75% respectively. Cycle for machining is 5 minutes. You walk back to the Assembly area and make your way to the spring production room. Spring production has three operators. The spring sets are cut and formed from rolls of spring steel. Each roll yields 50 sets of springs. The process takes 4 hours per roll and adds 0.5 per set to the total cost. OEE is 85% and scrap rate is 0%. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 37

41 Exercises Part A. Draw a wall value stream map using the template cut outs for the product showing the customer, inventories, and processes.. Show the data associated with the inventory, activities, and any costs. Part B. Calculate how many days of inventory you have at each point.. Identify useful summary metrics for the map. 3. Identify what charts would be useful to visualize the value stream and mark these up. Part C. Follow the step by step tutorial on the following pages to bring the wall map into evsm and create the map electronically. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 39

45 Plant Activity Plant Activity Added OEE Input Percent % Added OEE Input Percent % Stations Stn Stations Stn Scrap Percent % Activity Scrap Percent % Activity Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 43

47 Plant Activity Plant Activity Added OEE Input Percent % Added OEE Input Percent % Stations Stn Stations Stn Scrap Percent % Activity Scrap Percent % Activity Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 45

51 Quick Manufacturing Tutorial This tutorial will guide you through the steps to draw the following map using the Quick Manufacturing stencil. Z000 Summary Lead 6.68 Total Value 9.00 Added Value Added 0.3 % Percent Takt 8.40 Process.50 Per Unit A000 Spring Steel Rolls 00 Roll 6.00 Added 300 Roll A000 Machine and form caliper springs 3.00 Pre OEE Roll A0030 Springs Added 0.00 A060 all Operator Z0030 all Scrap s Total Scrap 467. Z030 all Summary Total Value 8 A030 Customer Demand Customer 500 Share % 00 % Effective Demand all Z050 Summary Lead 6.95 Total Value Added Value Added 0.48 % Percent Takt 8.40 Process 3.80 Per Unit OEE Percent % Added OEE Input Percent Roll Scrap Percent 0 % % Resource Quantity RQ Resource Resource Rate 0 Resource 04. Utilization % Resource PT 5 7 Resource PT 0 Resource PT.50 0 A070 all Machine Resource Quantity RQ Resource 4 Resource Rate 5 Resource 9.0 Utilization % 5 A0050 A0070 A0090 A00 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE Added Pre OEE Added Pre OEE Added Pre OEE Added OEE Percent % OEE Percent % OEE Percent % OEE Percent % Added Stations OEE Input Percent Stn Scrap Percent 0 % % Added OEE Input Percent % Added Scrap Percent 0 % OEE Input Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 49

53 Step : Start evsm On your Desktop, click the Start evsm icon. If you see a message like this, you must Enable macros. 4 Click Trust all from publisher to avoid the security notice in future. 3 Click to enable macros. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 5

54 Step : Learn evsm Basics Avoid re-sizing evsm shapes. Instead grow the drawing page when needed. To resize the page, hold down the Ctrl key, and then drag any page edge to the required size. This method works on all four edges of the page. 5 Save your Visio file and then insert a new page via the rightmouse menus on the page-tabs. 5 VSM Quick_eVSM Copyright 05 The evsm Group, All Rights Reserved

55 evsm Help resources are available in the Learn module of the toolbar. Hover over each help button to learn what it does. 3 Blue icons in the main stencil represent families of shapes. Drag out the Transport icon. 4 Use the shape s right-mouse menus to turn it into a car 6 Zooming: -Ctrl + Shift = Drag Zoom Options -Whole page view in Visio 003/007: Ctrl + W -Whole page view in Visio 00/03: Ctrl + Shift + W Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 53

57 Quick Mfg Stencil Overview Below is an overview of the Quick Mfg stencil shapes. **DRAG RED SHAPES OUT FIRST** Green icons represent Centers Yellow icons are additional add-on variables to add to Centers White icons represent Summary Centers Purple icons are the graphs and other charts Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 55

58 Step 3: Using the wall map sketcher Click the Wall Map button in the toolbar to import a wall map picture into evsm. Wall Map Click the Insert Wall Map button to browse for the image on your computer. 3 Draw a rectangle over any one process box to scale the picture. 4 Click Done when finished. 56 Copyright 05 The evsm Group, All Rights Reserved

59 5 Map visibility can be switched on/off and transparency can be set in this form as well. 6 Click OK to start sketching over the picture. 7 Delete the wall picture. Click the Wall Map button again to bring up the form. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 57

60 evsm Data QuickMfg Step 4: Initiate the map for Quick Manufacturing Lite Click the Open button. Select Manufacturing and click OK. Open Customer Center The Manufacturing stencils will open on the left. For this tutorial, use the Quick Mfg LT. Center 3 Drag out the two red icons first. This is very important! 4 Select the units type and currency for the map. 8 Enter available hours per week here. This is actual work hours after subtracting break time. Year Units day 58 Copyright 05 The evsm Group, All Rights Reserved

61 A000 all Customer 5 Align all new shapes to the grid as you drop them. Customer Demand 500 Share % 00 % Effective Demand 6 Enter customer demand here. 7 Leave fields alone. They will be calculated automatically. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 59

62 evsm Data QuickMfg Step 5: Adding Custom Unit Converters 3 Click the NUM button in the toolbar. NUM 4 Click the New Unit button, type, and click OK. Create another unit named Roll and click OK. 5 Double-click each field to match the appropriate units converters. Drag out two Units Converter shapes from the Quick Extras stencil and glue to the existing Center. Units 70 Year 5 5 day Roll 50 Double-click the bottom field to change to. 60 Copyright 05 The evsm Group, All Rights Reserved

63 A000 all Customer Demand Customer 500 Share % 00 % Effective Demand 6 Double-click the units for Customer Demand and change the numerator to. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 6

64 Unit Converters Usage Secs/s, s/s units converters are hidden Made visible through NUM button in the toolbar NUM Visibility of a unit converter can be switched on or off. 6 Copyright 05 The evsm Group, All Rights Reserved

65 Unit families eliminate errors when changing units Only units will appear when double-clicking on s to change to s If desired unit does not appear: Create a new unit -- OR -- Place a units converter on map Use NUM button in toolbar to create the new unit New unit will require units converter to connect default unit to new unit NUM New unit will appear in Select Unit window when double-click unit (family) If desired unit was in the NUM, add a units converter to the map Built-in error proofing to prevent incompatible units Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 63

66 evsm Data QuickMfg Step 6: Draw the flow The green shapes are called Centers. Use the centers to represent the flow. Activity Center Center A0030 A000 Type Process xx x.xx Sec Pre OEE OEE Percent % If the VA and NVA timeline is not lined up, use the Align line command in the right-mouse button menu. Sec Year Roll Units day 64 Copyright 05 The evsm Group, All Rights Reserved

68 Working with the timeline Shift the entire timeline up or down, use Select line in the right-mouse menu If that option doesn t appear in the menu, make sure you have the entire VA or NVA shape selected and try again Align line function also in the right-mouse menu will create the ladder timeline for you if the VA and NVA shapes are not correctly aligned, as shown below Disable Flying Connector Select line Align line 66 Copyright 05 The evsm Group, All Rights Reserved

70 evsm Data QuickMfg Step 7: Complete the flow and enter data If text does not fit, avoid resizing evsm shapes. Instead, make the font smaller. A080 Spring Steel Rolls 0 Roll A090 Machine and form caliper springs 3 Pre OEE 4 Sec Roll OEE Percent % A000 Springs 50 3 Check to make sure you have the appropriate units. If not, double-click the unit to change it. A0030 A00 A000 Casting s Machine A00 Machined s 4 Polish Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Year Roll Units day 68 Copyright 05 The evsm Group, All Rights Reserved

71 Complete as shown below, including annotation, data values, and units. A000 Customer all Customer Demand 500 Share % 00 % Effective Demand 4 Double-click the operator number on each center to change it. A040 A060 A030 Polished s 4 Assemble A050 Cutters Package A070 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 69

72 Fractional Units Fractional units makes specifying and computing demand quantities or production times easier Provides better control of data entry and display Fractional units changed like any other unit on map using the NUM button in the toolbar 70 Copyright 05 The evsm Group, All Rights Reserved

73 Data Entry Hints A000 A000 Type xx Process x.xx Input values with a default x.xx are mandatory and require a numeric value otherwise the map will not solve Non-Value Added = / Customer Demand When entering data use tab key to go to next NVU Non-Value Added and Value Added ladders are already glued to Activity Center and Center, respectively The standard NVUs on an Activity Center are required for calculations and MUST NOT be deleted Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 7

74 evsm Data QuickMfg Step 8: Add Arrows from Main Stencil A090 A080 Spring Steel Rolls Machine and form caliper springs 3 A000 Springs 0 Roll 4 50 Pre OEE Roll OEE Percent % Sec Glue all arrows at both ends. A0030 A00 A000 Casting s Machine A00 Machined s 4 Polish Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Year Roll Units day 7 Copyright 05 The evsm Group, All Rights Reserved

75 A000 all Customer Demand Customer 500 Share % 00 % Effective Demand 3 Use the right mouse button menu of the arrows to turn into a Push arrow. A040 A060 A030 Polished s 4 Assemble A050 Cutters Package A070 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Drag the arrows from the Main stencil on the right. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 73

76 evsm Data QuickMfg Step 9: Add Transport shapes A090 A080 Spring Steel Rolls Machine and form caliper springs 3 A000 Springs 0 Roll 4 50 Pre OEE Roll OEE Percent % Sec A0030 A00 A000 Casting s Machine A00 Machined s 4 Polish Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Year Roll Units day 74 Copyright 05 The evsm Group, All Rights Reserved

77 A000 all Customer Demand Customer 500 Share % 00 % Effective Demand Use the right mouse button menu to change the shape to have No Frame and switch into a Train icon. Glue transport shape to arrow. A040 A060 A030 Polished s 4 Assemble A050 Cutters Package A070 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 75

78 Transport, Transmit, and Flow Shapes Transport, Transmit, and Flow Shapes now have text box framed to allow data values to be added if needed If data is added to shape, an Operation Tag and Path Locator needs to be added To remove frame, right-click on shape and select Frame Icon Frame All Frame Icon No Frame Frame All (Default) Frame Icon No Frame Use Text Block tool to move text 76 Copyright 05 The evsm Group, All Rights Reserved

79 Blue Stack Shapes Blue icon stack has other shapes to choose Right-click on shape and select desired shapes Use the Stack Help button in the toolbar to see complete list of shapes in a stack after selecting a blue or green stack icon from a stencil Change Shapes By Foot Color Flags Computer Database Electronic Document Fax Instant Message Light Signal Meeting Pager Phone Post Print Sound Signal Spreadsheet Tube Carrier Wall LCD Web Form Whiteboard Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 77

80 evsm Data QuickMfg Step 0: Sequence Arrows Click the Sequence button. Sequence A080 Spring Steel Rolls A090 Machine and form caliper springs 3 A000 Springs 0 Roll 4 50 Pre OEE Roll OEE Percent % Sequence arrows are needed for upstream and downstream calculations. To add them, hold down the SHIFT key and select the green shapes in the order shown here. Sec A0030 A00 A000 A Casting s B Machine A00 Machined s C 4 D Polish Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Year Roll Units day 78 Copyright 05 The evsm Group, All Rights Reserved

81 A000 all J Customer Customer Demand 500 Share % 00 % Effective Demand A040 A060 A030 E Polished s 4 F Assemble A050 G Cutters H Package A070 I Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 79

82 Sequence Arrows Sequence Provide a means of generating tag numbers in upstream to downstream sequence (using the Tag button) Tag Provide a means of generating path numbers that comprehend all of the paths on the map (using the Path button) Path Are the basis for upstream/downstream calculations in the built-in evsm equations 80 Copyright 05 The evsm Group, All Rights Reserved

84 evsm Data QuickMfg Step : Sequence Path A090 A080 Spring Steel Rolls A Machine and form caliper springs 3 B A000 C Springs 0 Roll 4 50 Roll For the second path, hold the SHIFT key and select the green shapes A to D in the order shown. Then click the Sequence button. Pre OEE OEE Percent % Sec A0030 A00 A000 Casting s Machine A00 Machined s 4 Polish Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Year Roll Units day 8 Copyright 05 The evsm Group, All Rights Reserved

85 A000 all Customer Demand Customer 500 Share % 00 % Effective Demand The sequence arrows are now connecting path one. A040 A060 A030 Polished s 4 D Assemble A050 Cutters Package A070 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 83

86 evsm Data QuickMfg Step : Use Path to Generate Path ID s based on Sequence Arrows A000 A000 Spring Steel Rolls Machine and form caliper springs 3 A0030 Springs 0 Roll 4 50 Roll Pre OEE OEE Percent % Click Path to automatically generate Path numbers based on Sequence arrows. Path 3 Sec Click Tag again to re-order the tags based on the new sequence arrows. Tag A0050 A0070 A0040 Casting s Machine A0060 Machined s 4 Polish Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Year Roll Units day 84 Copyright 05 The evsm Group, All Rights Reserved

87 A030 all 4 Sequence arrow visibility can be The sequence arrows switched On/Off with the Show are now connecting Seq button. Try it. Show Seq. path one and two. Customer Demand Customer 500 Share % 00 % Effective Demand 5 These Path Locator tags are used to specify paths. You can manually change these. You can add new ones with copy/paste or from the main stencil on the right. Another way to specify paths is with Sequence arrows and the Path function. A0090 A00 A0080 Polished s 4 Assemble A000 Cutters Package A00 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 85

88 Path Locaters A000 Operation Tag Process Path Locater Path Locaters: Defines Path on map Allow filtering of specific charts and summaries on map There is also an all value for the Path Locater Are typically assigned using the Path button and AFTER sequence arrows have been applied A Path Locater designates a center as being on path AND filters all the variable calculations for the center by the same path 86 Copyright 05 The evsm Group, All Rights Reserved

89 Operation Tags Operation Tags: Provides short name for process step Identifies process step to Excel for calculations Defines the order in which data is plotted on charts Operation Tags MUST be -alpha and 4-numeric characters (ie: A000) Are typically assigned using the Tag button and AFTER sequence arrows have been applied Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 87

90 evsm Data QuickMfg Step 3: Summary by Path Drag out a two Summary Centers. Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % Sec Sec 3 Double-click to change this path ID to. A000 Spring Steel Rolls 0 Roll A000 Machine and form caliper springs 3 Pre OEE 4 Roll A0030 Springs 50 OEE Percent % Z050 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % Sec Sec Double-click to change this path ID to. Sec A0050 A0070 A0040 Casting s Machine A0060 Machined s 4 Polish Pre OEE OEE Percent % Pre OEE OEE Percent % Summary Sec Sec Year Roll Units day 88 Copyright 05 The evsm Group, All Rights Reserved

91 A030 all Customer Demand Customer 500 Share % 00 % Effective Demand A0090 A00 A0080 Polished s 4 Assemble A000 Cutters Package A00 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Sec Sec Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 89

92 evsm Data QuickMfg Step 4: Perform Calculations Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls 0 Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Springs 50 OEE Percent % Z050 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % When complete, note that all blue values show calculated results A0050 A0070 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Pre OEE OEE Percent % Pre OEE OEE Percent % Units 70 Year 5 5 day Roll 50 4 Double-click the unit if you would like to change it to minutes, or any other time measure. 90 Copyright 05 The evsm Group, All Rights Reserved

93 Click the Check button and fix any problems flagged. Check Click the Solve button to calculate. Solve A030 Customer all Customer Demand 500 Share % 00 % Effective Demand A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 9

94 First Check then Solve Users should first Check and then Solve the map. Check Button Check Performs comprehensive model checking Fixes obvious problem Provides list of outstanding issues Solve Button Solve Performs basic model checking Stops if there is any obvious issues like missing data values Solves the built-in equations and puts the results on the map Exports data to an Excel spreadsheet 9 Copyright 05 The evsm Group, All Rights Reserved

96 evsm Data QuickMfg Step 5: Add Takt Chart Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit Drag out CT/TT Chart icon Z Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % % A000 Spring Steel Rolls 0 CT / TT Chart 5.00 Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll OEE Percent % A0030 Springs Use the right mouse.50 button menu of chart icon and select Plot Chart 50 A0050 A0070 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish CT / TT Chart Pre OEE OEE Percent % Pre OEE OEE Percent % Year Roll Units day 94 Copyright 05 The evsm Group, All Rights Reserved

97 3 Here is the chart. Note the bottleneck in the Machine activity. A030 all 6 / Takt Chart 4 Customer / Customer Demand 500 Share % 00 % Effective Demand A000 A0050 Machine and form ca.. Machine A0070 A0090 A00 Polish Assemble Package Activity Takt Per Unit Legend A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 95

98 evsm Data QuickMfg Step 6: Try Add-on Calculations: Stations Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls 0 Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Springs 50 OEE Percent % Z050 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % Run Solve and note the changes in the chart. Solve A0050 A0070 Activity Center A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Activity Stations Pre OEE Pre OEE OEE Percent % OEE Percent % Stations Stn Drag out the Stations 5.00 add-on and glue to the Machine Activity Center. Year Roll Units day 96 Copyright 05 The evsm Group, All Rights Reserved

99 A030 all / / Takt Chart CT / TT Chart Customer Demand Customer 500 Share % 00 % Effective Demand Activity Takt Per Unit 0 A000 A0050 Machine and form ca.. Machine A0070 A0090 A00 Polish Assemble Package Legend A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Pre OEE OEE Percent % Pre OEE OEE Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 97

100 evsm Data QuickMfg Step 7: Try Add-on Calculations: OEE, Scrap, Activity Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls 0 Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Springs 50 OEE Percent % Z050 Summary OEE Input Percent 85 % Scrap Percent 0 % Lead Activity Center Activity OEE Direct Total Value Added Value Added Percent Takt Process Per Unit % Run Solve and note the changes in the chart. Solve A0050 A0070 Activity Scrap A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Activity Pre OEE Pre OEE OEE Percent % OEE Percent % Stations OEE Input Percent 75 Stn % OEE Input Percent 95 % Scrap Percent 0 % Year Roll Units day 98 Copyright 05 The evsm Group, All Rights Reserved

101 A030 all / / Takt Chart CT / TT Chart Activity Takt Per Unit OEE Remainder Loss DownStr Loss Scrap Loss Customer Demand Customer 500 Share % 00 % Effective Demand A000 A0050 Machine and form ca.. Machine A0070 A0090 A00 Polish Assemble Package Legend A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Pre OEE OEE Percent % OEE Input Percent 80 % Scrap Percent 0 % Pre OEE OEE Percent % OEE Input Percent Activity 95 4 % Double-click to change to / Drag out the appropriate add-ons to.00 each center. Be sure to glue the add-ons to the center Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 99

102 evsm Data QuickMfg Step 8: Hide/Show Variables Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit Z Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % % A000 Spring Steel Rolls Added Roll Roll A000 Machine and form caliper springs 3.00 Pre OEE Roll OEE Percent % Added OEE Input Percent Scrap Percent 0 % Click the Views button in the toolbar. 85 Views set % A0030 Added Springs A0050 A0070 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Added Pre OEE Added Pre OEE OEE Percent % OEE Percent % Added Stations Stn Added OEE Input Percent % Scrap Percent 0 % OEE Input Percent 75 % Copyright 05 The evsm Group, All Rights Reserved

103 Year Roll Units day A030 all Customer Customer Demand 500 Share % 00 % Effective Demand Check the visibility box Check the Added visibility box and click OK. A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE OEE Percent % Added Scrap Percent 0 % OEE Input Percent % Added Now that the Added and variables are visible, fill in the data values for Added and 0.5 click the Solve button. Solve Pre OEE OEE Percent % Added Activity OEE Input Percent % Added Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 0

104 evsm Data QuickMfg Step 9: Chart Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls Added 0 Roll Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Added Springs OEE Percent % Z050 Summary Added set Lead 6.95 Scrap Percent 0 % Total Value Added Value Added Percent Takt Process Per Unit % 5.00 OEE Input Percent %.50 3 Use the right mouse button A0050 menu of chart icon and select Plot Chart A0040 Casting s.00 Machine A0060 Machined s A Polish Chart Drag out the Chart from the Quick Mfg stencil. Added Chart Pre OEE OEE Percent % Added Stations OEE Input Percent Stn Scrap Percent 0 % % Added Pre OEE OEE Percent % Make sure Added the fractional OEE Input units for the Added 95 Percent variable match. Doubleclick to change it. % Copyright 05 The evsm Group, All Rights Reserved

105 Year Roll Units day A030 all 70 Chart 60 Customer / Customer Demand 500 Share % 00 % Effective Demand Added Added Scrap 0 A000 A000 A0030 A0040 A0050 A0060 A0070 A0080 A0090 A000 A00 A00 Spring Steel Rolls Machine and form ca.. Springs Casting s Machine Machined s Polish Polished s Assemble Cutters Package Boxes Legend A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE Added Pre OEE Added OEE Percent % OEE Percent % Added Scrap Percent 0 % OEE Input Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 03

106 evsm Data QuickMfg Step 0: Plot Lead Chart Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % Drag out Lead Chart icon. Z050 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls Added Roll Lead all Roll A000 Machine and form caliper springs 3.00 Pre OEE Roll OEE Percent % Added Scrap Percent 0 % OEE Input Percent set A0030 Added Springs icon % and select Plot Use the right mouse button menu of chart Ladder Chart Lead Chart A0040 Casting s 000 A0050 Machine.00 5 A0060 Machined s A0070 See how the lead times for the two paths match Polish the Summaries 50 5 Lead Summary Added A000 Machine and form caliper springs A0030 Springs Pre OEE OEE Percent % 0.50 Pre OEE OEE Percent % Added Added A0040 A0060 A0080 A000 A00 Casting s Machined OEE Input Stations s Polished Stn s Cutters Boxes 95 % Percent A000 Spring Steel Rolls Scrap Percent 0 % A000 Cutters OEE Input Percent % A00 Boxes Added Copyright 05 The evsm Group, All Rights Reserved

107 Year Roll Units day A030 all Customer Demand Customer 500 Share % 00 % Effective Demand A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE Added Pre OEE Added OEE Percent % Legend Added Non Value Added 3 Scrap Value Percent Added 0 % OEE Input 80 % Percent OEE Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 05

108 evsm Data QuickMfg Step : Resource Modeling Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls Added 0 Roll Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Added Springs OEE Percent % Z050 Summary Added set Lead 6.95 Scrap Percent 0 % Total Value Added Value Added Percent Takt Process Per Unit % OEE Input Percent appropriate Resource Centers to 85 Add Resource Pipes for the Activity Centers. Make sure the correct unit is changed for the data on the Resource Pipe. %.50 Resource PT 5 Resource Center A0050 A0070 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Added Pre OEE Added Pre OEE OEE Percent % OEE Percent % Added Stations Stn Added OEE Input Percent % Scrap Percent 0 % OEE Input Percent 75 % Copyright 05 The evsm Group, All Rights Reserved

109 Year Roll Units day Drag out the Resource Center from the Quick Mfg stencil. Right-click the center to change into a Machine. A070 A Machine all A030 Customer Demand Customer 500 Share % 00 % Effective Demand all A060 Operator Resource Quantity Resource Resource Rate all RQ Resource Utilization % Resource PT 0 Resource PT 0 3 Resource Quantity Resource Resource Rate RQ 4 5 Resource Utilization % To add Resource Pipes, hold down the SHIFT key and select the Resource Center and then the Activity that it is being piped into, then click the Pipe button. Pipe A0090 A00 A0080 Polished s 4.00 B Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE Added Pre OEE Added OEE Percent % OEE Percent % Added Scrap Percent 0 % OEE Input Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 07

110 evsm Data QuickMfg Step : Resource Balance Chart Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls Added 0 Roll Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Added Springs OEE Percent % Z050 Summary Added set Lead 6.95 Scrap Percent 0 % Total Value Added Value Added Percent Takt Process Per Unit % OEE Input Percent 5.00 Click the Solve button to update the new calculations Solve 85 %.50 Resource PT 5 Resource Balance Chart A0050 A0070 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Drag out the Resource Balance Chart shape. Added Resource Balance Pre OEE OEE Percent % Added Stations OEE Input Percent Stn Scrap Percent 0 % % Added Use the right mouse button menu of chart icon and select Plot Chart Pre OEE OEE Percent % Added OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved

111 600 Resource Balance Chart Units 70 Year 5 5 Roll day 00 / Assemble Polish Assemble Effective Resource Resource Usage PT A030 Customer Demand Customer 500 all 0 Operator A060 Machine A070 Legend Share % 00 % Effective Demand A060 Operator Resource Quantity Resource Resource Rate all RQ 0 Resource Utilization % Resource PT 0 Resource PT 0 A070 Machine Resource Quantity Resource Resource Rate all RQ 4 5 Resource Utilization % A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE Added Pre OEE Added OEE Percent % OEE Percent % Added Scrap Percent 0 % OEE Input Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 09

112 evsm Data QuickMfg Step 3: Kaizen Improvements Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls Added 0 Roll Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Added Springs OEE Percent % Z050 Summary Added set Lead 6.95 Scrap Percent 0 % Total Value Added Value Added Percent Takt Process Per Unit % 5.00 OEE Input Percent %.50 Resource PT 5 A0050 A0070 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Added Very high level of Casting inventory Pre OEE OEE Percent % Added Stations OEE Input Percent Stn Scrap Percent 0 % % Added Machine process is a bottleneck because of low OEE Pre OEE Kaizen 0.50 Properties form, such as Impact OEE Percent % Added OEE Input Percent Right click kaizen and select Edit Kaizen. Add relevant information in the and Ease of Implementation values. % Kaizen Data 0 Copyright 05 The evsm Group, All Rights Reserved

113 Year Roll Units day 3 Click the Kaizen Export button in the toolbar to create a kaizen report in Excel. Kaizen Export A030 Customer all Customer Demand 500 Share % 00 % Effective Demand A060 Operator Resource Quantity Resource Resource Rate all RQ 0 Resource Utilization % Resource PT Resource PT Reduce assemble CT 0 A070 Machine Resource Quantity Resource Resource Rate all RQ 4 5 Resource Utilization % 004 Increase delivery frequency to customer A0080 Polished s A Assemble A000 Cutters A00 Drag out Kaizen starbursts from the Quick Extras stencil..00 Package A00 Boxes Added Pre OEE Added Pre OEE Added OEE Percent % OEE Percent % Added Scrap Percent 0 % OEE Input Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping

114 evsm Data QuickMfg Step 4: Kaizen Impact Matrix 5 4 Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit A000 Spring Steel Rolls 0 Roll A000 Kaizen Impact Matrix % Added Roll Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Added Springs Impact On Value 3 Z050 Summary Lead Total Value Added 004 Value Added.75 Percent Takt Process Per Unit % OEE Percent % Added OEE Input Percent set Scrap Percent 0 % %.50 Resource PT 5 A0050 A A0040 Casting s Added Very high level of Casting inventory.00 Machine 5 Ease Qty Per Of Cycle Implementation Pre OEE OEE Percent % Added Stations OEE Input Percent Stn Scrap Percent 0 % % A0060 Machined s Added Machine process is a bottleneck because of low OEE 4.00 Pre OEE Polish OEE Percent % Added OEE Input Percent % Kaizen Data Copyright 05 The evsm Group, All Rights Reserved

115 Year Roll Units day A030 all Customer Drag out the Kaizen Impact Matrix and right-click to plot. Kaizen Impact Matrix Customer Demand 500 Share % 00 % Effective Demand A060 Operator Resource Quantity Resource Resource Rate all RQ 0 Resource Utilization % Resource PT Resource PT Reduce assemble CT 0 A070 Machine Resource Quantity Resource Resource Rate all RQ 4 5 Resource Utilization % 004 Increase delivery frequency to customer A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE Added Pre OEE Added OEE Percent % OEE Percent % Added Scrap Percent 0 % OEE Input Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 3

116 evsm Data QuickMfg ACME Plant Current State Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls Added 0 Roll Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Added Springs OEE Percent % Z050 Summary Added Lead Total Value Added Value Added Percent Takt Process Per Unit % 5.00 Scrap Percent 0 % OEE Input Percent %.50 Resource PT 5 A0050 A0070 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Added Pre OEE Added Pre OEE OEE Percent % OEE Percent % Added Stations Stn Added OEE Input Percent % Scrap Percent 0 % OEE Input Percent 75 % Copyright 05 The evsm Group, All Rights Reserved

117 Year Roll Units day Z0030 Scrap s Total Scrap 47.5 all Z030 all Summary Total Value A030 Customer all Customer Demand 500 Share % 00 % A060 Operator all Effective Demand Resource Quantity Resource Resource Rate RQ Resource Utilization % 7 Resource PT 0 A070 Machine all Resource PT 0 Resource Quantity Resource Resource Rate RQ 4 5 Resource Utilization % A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE Added Pre OEE Added OEE Percent % OEE Percent % Added Scrap Percent 0 % OEE Input Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 5

118 ACME Resource Modeling Exercise With your group, read the information below and then:. Model the resources for the activity.. Show the data associated with the resource handling as well as resource pipe data. 3. Calculate the map. 4. Identify what charts would be useful to visualize the value stream and mark these up. 5. Identify where there is a bottleneck. Background and Overview ACME sells Surgical Cutters which are made from a combination of springs and kits. The plant line first creates the polished kits from the casting sets and then joins the springs in the Assemble step. You take a second value stream walk with the plant supervisor to model the resource allocation for the activity processes. Value Stream Walk The plant supervisor explains how resources are coming from technicians as well as machines. You first notice that the Assemble activity has two different resources being piped into it. The first is a machine that runs 4 hours a day with a resource quantity of at a cost of 5 an hour. The second resource is an operator that works hours a days with a resource quantity of at 0 an hour. Both have a resource process time of 0 minutes. The operator is also shared at the Polish activity with a resource process time of 5 minutes. 6 Copyright 05 The evsm Group, All Rights Reserved

120 Multi-Station Workshop BSQI has augmented their old machine with a new machine for making machined kits to increase capacity. Insert a new page and use the Open button to select the Mfg Multi Station Wizard to calculate the equivalent capacity from the two machines as shown below. A0040 A0050 Z0060 Multiple Station Equiv. Old Machine New Machine set _M 0 _M 0 Stations.00 Stn Qty Per Cycle_M Stations_M Activity _M OEE Percent_M Per CT Per All Stations QPC Contributor Per set Stn % ItSq Qty Per Cycle_M Stations_M Activity _M OEE Percent_M Per CT Per All Stations QPC Contributor Per set Stn % ItSq OEE Percent % Activity MS CT Per MS Per MS Per Roll Units Copyright 05 The evsm Group, All Rights Reserved

121 Improvement Workshop Part C. Identify any improvements that can be made to the process.. Use kaizen bursts on the map, to capture and prioritize all the improvements you identified. 3. Using Map Copy as a starting point, design a future state map for ACME Surgical Cutter production. Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 9

122 evsm Data QuickMfg ACME Plant Future State Z000 Summary Lead Total Value Added Value Added Percent Takt Process Per Unit % A000 Spring Steel Rolls Added Roll Roll A000 Machine and form caliper springs 3.00 Pre OEE 4 Roll A0030 Added Springs OEE Percent % Z050 Summary Added Lead Total Value Added Value Added Percent Takt Process Per Unit %.00 Scrap Percent 0 % OEE Input Percent %.00 Resource PT 5 A0050 A0070 A0040 Casting s.00 Machine A0060 Machined s 4.00 Polish Added Pre OEE Added Pre OEE OEE Percent % OEE Percent % Added Stations Stn Added OEE Input Percent % Scrap Percent 0 % OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved

123 Year Roll Units day Springs WIP will go down because Assemble no longer a bottleneck. Z0030 Scrap s Total Scrap all Z030 all Summary Total Value A030 Customer Demand Customer 500 all Share % 00 % A060 Operator all Effective Demand Resource Quantity Resource Resource Rate RQ Resource Utilization % 7 Resource PT 0 A070 Machine all Resource PT 0 Resource Quantity Resource Resource Rate RQ 4 5 Resource Utilization % savings because of reduced Scrap. A0090 A00 A0080 Polished s 4.00 Assemble A000 Cutters.00 Package A00 Boxes Added Pre OEE Added Pre OEE Added OEE Percent % OEE Percent % Added Scrap Percent 5 % OEE Input Percent % Added Activity OEE Input Percent % Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping

124 ACME Plant Dashboard Current State Lead Lead Summary A0040 Casting s A0060 Machined s A0080 Polished s A000 Cutters A00 Boxes A000 Spring Steel Rolls A000 Machine and form caliper springs A0030 Springs A000 Cutters.68 A00 Boxes 6.95 Future State Lead Lead Summary A0040 Casting s A0060 Machined s A0080 Polished s A000 Cutters A00 Boxes A000 Spring Steel Rolls A000 Machine and form caliper springs A0030 Springs A000 Cutters A00 Boxes Current State Future State Z070 Summary Z080 Summary Z000 Summary Z050 Summary Lead.68 Lead 6.95 Lead 7.88 Lead 3.65 Total Value Added Value Added Percent Takt Process Per Unit % Total Value Added Value Added Percent Takt Process Per Unit % Total Value Added Value Added Percent Takt Process Per Unit % Total Value Added Value Added Percent Takt Process Per Unit % Z0300 Scrap s Total Scrap 467. all Z090 all Summary Total Value Z0030 Scrap s Total Scrap all Z030 all Summary Total Value Copyright 05 The evsm Group, All Rights Reserved

125 Current State CT/TT Legend Non Value Added 0 / Takt Chart Value Added / Activity Takt Per Unit OEE Remainder Loss DownStr Loss Scrap Loss 0 A000 A0050 A0070 A0090 A00 Legend Legend Machine and form ca.. Machine Polish Assemble Package Non Value Added Value Added Future State CT/TT 9 / Takt Chart 8 7 / Activity Takt Per Unit OEE Remainder Loss DownStr Loss Scrap Loss 0 A000 A0050 Machine and form ca.. Machine A0070 A0090 A00 Polish Assemble Package Legend Copyright 05 The evsm Group, All Rights Reserved Plant Level Mapping 3

128 Mixed Model Slides References Creating Mixed Model Value Streams by Kevin Duggan Today s Factories Are Often Complex Lots of tailoring for customers Shared resources Many product variations Workfloor spaghetti Optimization of resources Uncertain demand from day to day No management time frame - Creating Mixed Model Value Streams by Kevin Duggan 6 Copyright 05 The evsm Group, All Rights Reserved

129 Mixed Model Value Streams Mixed Model means to produce a variety or mix of products or product variations through the same value stream at the pull of the customer. - Creating Mixed Model Value Streams by Kevin Duggan Ten Guidelines for Mixed Model. Do you have the right product families?. What is the takt time at the pacemaker? 3. Can the equipment support takt time? 4. What is the interval? 5. What are the balance charts for the products? 6. How will we balance flow for the mix? 7. How will we create standard work for the mix? 8. How will we create pitch at the pacemaker? 9. How do we schedule the mix at the pacemaker? 0. How do we deal with changes in customer demand? - Creating Mixed Model Value Streams by Kevin Duggan Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 7

130 Mixed Model Complexity 0 products, 9 to operations, 5 stations, overlapping capabilities Cycle times vary by product / operation / station / resource combination Have to avoid needing human computers to figure out what we need to improve Operations People Products Stations Value Stream Metrics 8 Copyright 05 The evsm Group, All Rights Reserved

132 A000 Processi ng (hr) Wait (hr) A000 Processi ng (hr) 7.50 Wait (hr) A0030 Processi ng (hr) Wait (hr) Production Mixed Model Improvement How can VS visualization effort be minimized AND give us useful results? Simple Simulation VSM Product 3606DIE SEL 3606GA S % Usage Product 3606DIE SEL 3606GA S % Usage Product 3606DIE SEL 3606GA S % Usage Op0 Op5 Op0 Pre OEE x.xx Sec Pre OEE x.xx Sec Pre OEE x.xx Sec Visuals OEE Percent % OEE Percent % OEE Percent % Excel Input Usage Factors and Charts Sec Sec Sec Improvement Ideas 30 Copyright 05 The evsm Group, All Rights Reserved

133 Production Period Studies Ideal Sequence? Lead s Production Periods Production Earliest release to production Required By Products Processing Studies Wait s Lead s Production Components Planned Downtime Queue Products Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 3

135 & Lead Sec/ / Takt Chart / Takt Chart A040 A060 A080 Mold Handles Sharpen Assemble Activity Takt 7 Changeover Loss6 Per Unit 5 Sec/ Legend 4 Activity Takt 3 DownStr Loss Scrap Loss Per Unit 0 A040 A060 A080 Legend Mold Handles Sharpen Assemble VSM Detail by Operation Drill A000 Wait Queue min A Pre OEE Drill.5 Sec OEE Percent % OEE Input Percent Stations Activity Activity Demand 00 % Stn Product Family Q/UT Product Demand P/UT Op Use VSM Use System Use % % % A VSM Q/UT Demand P/UT OEE Avail VSM Use System Use / % / % % Stations I/UT Station Demand P/UT OEE Avail Op Use VSM Use System Use % / % % % 0 Stn Stn Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 33

136 Benefits of Approach Standardized mixed model approach Common visual process understanding Applicable to machining and assembly VS See true capacity for complex VS See how changes in mix, product, equipment effect throughput & cost See how changes in staffing effect VS Help determine optimal staffing and inventory levels Do what if s for varying demand and products Help manage improvement projects Flowchart of Mix Model 34 Copyright 05 The evsm Group, All Rights Reserved

137 I_VS Worksheet "C" for Comment Row A Product Expected Production Value Stream ID Scissors Expected Production J A Value Stream Expected Production From: Product entering the first station To: When it leaves the last station User input value and can be compared to simulator output Excel Worksheet I_VS Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 35

138 evsm Data QuickMfg evsm Data QuickMfg Title A000 Title A000 Wait 0.00 Year 5 Wait 0.00 Year 5 DATE FILENAME REVISED Wait DATE FILENAME REVISED Wait 0 0 /6/ _TEST.VSD /6/04 Year mth Year mth /6/ _TEST.VSD /6/04 A000 5 A hr hr TITLE DESCRIPTION Op0 TITLE Op0 8 DESCRIPTION 8 A0030 A test model Wait.9 Wait.9 Wait Lead 3600 test model Wait.9 Lead.9 A0040 A Op5 Op A0050 Wait.9 Wait.9 A Op A0070 Wait 0.3 Wait 0.3 A Lead Summary A000 Op0 A0050 Wait.9 Wait.9 CT / TT Chart A0030 Wait A Op A0040 Op5 / Takt Chart A000 A Wait 0.3 Wait A0040 A0050 Wait 0.3 A0060 A0080 A0060 Op0.00 Lead Summary A000 Op0 CT / TT Chart A0030 Wait A0040 Op5 / Takt Chart A A0040 A0050 Wait A0060 A0080 A0080 A0060 Op0 A000 Op A000 Op A A0080 Op5 A A0080 Op5 A060 A0090 Wait A060 A0090 Wait A0090 A0090 Wait 0.43 Wait 0.43 Wait A000 Op30 Wait A000 Op30 Activity Takt Per Unit 0.43 Activity Takt Per Unit 0.43 Legend A040 Op40 Legend A040 Op40 A000 A A060 Op50.00 A060 Op50 Op Op Legend Value Added Legend Value Added A030 Non Value Added A030 Non Value Added Wait 0.00 Wait 0.00 Wait Wait 0 0 A040 A Op Op A050 A050 Wait 0.06 Wait 0.06 Wait Wait A060 A A070 A070 Op Op Customer Demand Customer Demand 3.5 Customer Share % 00 % Effective Demand Customer Share % 00 % Effective Demand 9.00 Z000 Z000 Summary Lead Total Value Added Value Added Percent Summary Lead Total Value Added Value Added Percent Takt Process Per Unit Takt Process Per Unit all % all % Value Stream ID Each product type has a value stream ID One map is generated per value stream ID Value stream ID s correspond to product families Product A A A Value Stream Blade Blade Axle A Axle Excel Worksheet Excel Worksheet Value Stream Untangling Product A A Value Stream Blade Blade VSM_Blade Units / Op0 Op5 Op0 Op5 System Use = 98% A Axle VSM_Axle A Axle Units Op30 Op40 Op50 / Op0 Op5 Op0 Op5 Op30 Op40 Op50 System Use = % 36 Copyright 05 The evsm Group, All Rights Reserved

139 Value Stream Complexity Dedicated Balanced VS Dedicated Unbalanced VS Product Family VS Shared Resource Across VS s Job Shop Increasing Complexity Dedicated Balanced VS A Stn Stn Stn 3 Single Product Type Equal CT at each station No waiting Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 37

140 Dedicated Unbalanced VS 3 A Stn Stn Stn 3 Single Product Type Unequal CT at each station WIP ahead of slower station (Stn ) Idle time at faster stations (Stn, Stn 3) Product Family VS B 0.5 hr C/O 4 hr C/O hr C/O A 3 Stn Stn Stn 3 Product Types / One value stream C/O s consume production time Unequal CTs create WIP & Idle Larger the inequality between CTs, the greater the losses 38 Copyright 05 The evsm Group, All Rights Reserved

141 Shared Resources evsm Mix Understanding how much of a shared resource is used by each value stream can help untangle the value streams Shared Resources 3 % of Shared Resources Job Shop Stn Stn Stn 3 Stn 4 Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 39

142 Floating Resources / Sequencing Stn Stn Stn 3 A B If we made sure that we are making at max one B at any time and all operators float across Stn s,, and 3 (x-trained) then we only need 4 operators I_Demand Worksheet "C" for Comment Row Job Product Job Qty Earliest Release Required By Last Operation J A 0 40 Copyright 05 The evsm Group, All Rights Reserved

143 Job Qty Job # J5 A 3 Job Qty Stn 4 The # of products in a job and that stay together through each operation Job Qty is 3, so once Stn 4 performs an operation on A, then it performs the same operation on the other two A s Works like a min lot size, you CANNOT break up a job other than by splitting it into jobs on the I_Demand sheet Excel Worksheet I_Demand Excel Worksheet Earliest Release J A Earliest Release for Job = s Stn 54 Stn 54 is available to do the FIRST operation on A Job has to wait to get its FIRST operation done until its earliest release (to production) of days Excel Worksheet I_Demand Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 4

144 Required By J A Stn 5 Stn 3 Customer When is production for Job required to complete (as measured from 0) User input value and can be compared to simulator output Excel Worksheet I_Demand Excel Worksheet Last Operation J A Last Operation = Drill Provides means of specifying WIP in the value stream as a starting condition Last Operation references the operation that has been completed for this job Excel Worksheet I_Demand Excel Worksheet 4 Copyright 05 The evsm Group, All Rights Reserved

145 I_Stn Worksheet "C" for Comment Row Station Pre-Start Uptime OEE % CT Percent CT Percent CT Percent / % / % / % Defaults Stn Shift Warmup Shift Shift OT Pre-Start Uptime J A J A Stn 54 Pre-Start Uptime = 80 s The first two jobs could have their next operation done by Stn 54 Stn 54 has 80 hours of undeclared work before it can start on the declared demand Excel Worksheet I_Stn Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 43

146 OEE J A Op = Drilling CT = 5 s Stn 54 OEE = 85% Product A requires a Drilling Op at Stn 54 with a of 5 min If the OEE of Stn 54 = 85%, then the Effective is taken as: 5/0.85 = 5.88 mins Excel Worksheet I_Stn Excel Worksheet Shift Warmup Shift Warmup Shift / 45 CT % 0 7 / 45 CT % 00 at the beginning of a shift where there may be different productivity levels Excel Worksheet I_Stn Excel Worksheet 44 Copyright 05 The evsm Group, All Rights Reserved

147 Percent Stn 50 / 45 Shift % 00 For Stn 50 / 60 Shift % 85 Shift runs with the nominal resources and achieves the nominal cycle time Shift runs with extra resources and is able to achieve a faster cycle time and hence a reduced cycle time % Excel Worksheet I_Stn Excel Worksheet I_Ops Worksheet "C" for Comment Row Station Product Operation Op Seq Cycle Qty Per Cycle imum Lot Size Preferred Lot Size imum Post- Op Wait ID ID ID # C M SC Red Machine Manual Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 45

148 Op Sequence A 0 0 Prepare Mold Sequence of operations for a product A must go through the Op Sequence 0, 0 in that order Each operation name must have a unique operation sequence number Excel Worksheet I_Ops Excel Worksheet Qty Per Cycle = Prepare A Stn 5 Number of items processed by a particular operation within a single cycle at that station Excel Worksheet I_Ops Excel Worksheet 46 Copyright 05 The evsm Group, All Rights Reserved

149 Preferred Lot Size Stn 54 J9 A J5 A J A Preferred product lot size for an operation on a station Simulator accommodates by allowing same products to jump the queue Contingent on input materials availability Excel Worksheet I_Ops Excel Worksheet Job Qty & Preferred Lot Size Job Product Job Qty A 8 A B A B A Run Job : Ran 8 of A Run Job 3: Ran 8 (6 total) of A Run Job : Ran 5 of B Drilling Stn 4 = Preferred Lot Size = 0 for A Preferred Lot Size = 5 for B Excel Worksheet I_Ops / I_Demand Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 47

150 imum Post Op Wait J A Stn 54 Stn 56 0 s 30 s 4 s A must wait a minimum 30 mins from exiting Stn 54 and before entering Stn 56 Used to model transfer times Excel Worksheet I_Ops Excel Worksheet Manual J B J A Drilling Stn 5 If desired for Drilling is the same for products A and B = 0 hrs BUT: A needs 0 hrs of labor (Manual ) and B needs only 0 hrs of labor THEN: We need a minimum people on Stn 5 when processing A and one person when processing B Excel Worksheet I_Ops Excel Worksheet 48 Copyright 05 The evsm Group, All Rights Reserved

151 I_Assy Worksheet "C" for Comment Row Product Operation Component A Component B ID ID ID Qty Per ID Qty Per C SC Red Machine Comp A Comp B Assembly A A A J Assemble Scissors A Run Job : Ran 8 of A Run Job 3: Ran 8 (6 total) of A Run Job : Ran 5 of B Excel Worksheet I_Assy Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 49

152 I_Tracks & Alts "C" for Comment Row Track ID Operation Operation C T00 Machine Polish Alternatives and Tracks Machine J A Prepare First Track Mold Sharpen Assemble Second Track A is produced via First or Second Track Actual track selected during simulation based on preference (First Only, Second Only, First If Available, Second If Available) Excel Worksheet I_Tracks / I_Alts Excel Worksheet 50 Copyright 05 The evsm Group, All Rights Reserved

153 I_CO Worksheet "C" for Comment Row Station From Product From Operation Changeover Changeover / CO To Product To Operation C M SC Red Machine SC Blue Machine Changeover Milling A 45 s Cut B Stn 3 Stn 3 and cost to go from product to product and operation to operation at a particular station 45 s to have Station 3 ready to cut products of type B when it is currently setup for Milling products of type A Excel Worksheet I_CO Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 5

154 S_Make Virtual Factory Product Expected Production Value Stream ID Op Name Op Sequence ALT:ID ALT:PREF ALT:TRACK Comp ID Comp Qty Workstation imum Lot Size Preferred Lot Size Wait Pre-Start Uptime OEE Shift Shift Duration Manual Rate Per % / A Scissors Drill Stn 0 00 Shift Stn Shift Sharpen Stn Shift Sim_Stations Station Pre-Start Uptime Start P/UT P/PDT I/UT I/PDT Start End End ID Stn P/UT P/UT I/UT I/PDT Stn - - Initial J - A Stn Drill Drill Stn Stn Copyright 05 The evsm Group, All Rights Reserved

155 P/UT Drilling J B Milling J C Stn 3 Idle for Stn A station s processing time (P) during uptime (UT) P/UT = 5.5 s above Excel Worksheet Sim_Stations Excel Worksheet P/PDT Milling B Milling B Stn 4 s Planned downtime (PDT) = 3 s s Stn Product is in-station during planned downtime Product B starts, is stopped during planned downtime, and then resumes P/PDT = 3 s Excel Worksheet Sim_Stations Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 53

156 I/UT Milling B s Cutting A Stn Stn 3 Idle time (I) at station during uptime (UT) Stn 3 just finished Cutting Product A and has an idle time of hrs until the next job Excel Worksheet Sim_Stations Excel Worksheet I/PDT Milling B s Cutting A Stn Stn 3 Idle time (I) at a station during planned downtime (PDT) Excel Worksheet Sim_Stations Excel Worksheet 54 Copyright 05 The evsm Group, All Rights Reserved

157 Sim_Products Worksheet Started Earliest Require Start End Job Product Job Qty After Op Release d By P/UT P/PDT Q/UT Q/PDT Start End ID ID J A P/UT Q/UT P/UT J Stn Stn3 J Drill Sharpen J J 0.00 Q/UT J B Stn Stn 4 30 s 90 s Queue time (Q) of a product during uptime (UT) The Queue time during uptime of Job is s Excel Worksheet Sim_Products Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 55

158 Q/PDT J B Stn Stn 4 Queue time (Q) during planned downtime (PDT) Excel Worksheet Sim_Products Excel Worksheet Sim_VSM Worksheet Summary Product Summary Product Demand P/UT Q/UT VSM Use On System Us % % % Sharpen A Product Family VSM Summary Q/UT Product Demand P/UT Op Use VSM Use System Us % % Demand % P/UT Q/UT Activity TimSystem Use 0.00 A / / % VSM Q/UT Demand P/UT OEE Avail VSM Use System Us Station Summary / % / % % Station Demand Sum (P/UTSum (I/UT)VSM Use UtilizationSystem Use % % % Stations Stn I/UT Station Demand P/UT OEE Avail StnOp Use 0.00 VSM Use System 0 Us % / % % % Stn3.00 Stn Stn 0 Stn Copyright 05 The evsm Group, All Rights Reserved

159 Product Family Product Family Q/UT Product Demand P/UT Op Use VSM Use System Us % % % 0.00 A Op Use: % of this operation s P/UT hrs used for this product type VSM Use: % of the value stream s P/UT hrs used for this product type System Use: % of the system (all value streams) P/UT hrs used for this product type Excel Worksheet Sim_VSM Excel Worksheet Stations Stations I/UT Station Demand P/UT OEE Avail Op Use VSM Use System Us % / % % % Stn Stn 0 Stn Op Use: % of this operation s P/UT hrs supplied by this station VSM Use: % of the value stream s P/UT hrs supplied by this station for this operation System Use: % of the system (all value streams) P/UT hrs supplied by this station for this operation Excel Worksheet Sim_VSM Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 57

160 VSM VSM Q/UT Demand P/UT OEE Avail VSM Use System Us / % / % % Q/UT: Average wait time for a product ahead of this operation Post WIP: Average WIP after this operation P/UT: Average processing time for products at this operation VSM Use: P/UT hrs used at this operation as a percent of P/ UT hrs used by the value stream Excel Worksheet Sim_VSM Excel Worksheet Product Summary Product Summary Product Demand P/UT Q/UT VSM Use On System Us % % % A On %: % of products that are predicted to be complete ahead of user specified Required By time Excel Worksheet Sim_VSM Excel Worksheet 58 Copyright 05 The evsm Group, All Rights Reserved

161 VSM Summary VSM Summary Demand P/UT Q/UT Activity TimSystem Us / / % Demand: Overall value stream demand P/UT: Average processing time per product for the value stream Q/UT: Average wait time per product for the value stream Excel Worksheet Sim_VSM Excel Worksheet Stations Summary Station Summary Station Demand Sum (P/UTSum (I/UT)VSM Use UtilizationSystem Us % % % Stn Stn Stn Excel Worksheet Sim_VSM Excel Worksheet Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 59

163 Hand Exercises The following exercises will make you familiar with the terms and calculations in using the mixed model capability in evsm. Job Quantity Product 50 A J Operation Job Quantity Station Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 6

164 . Product / Station / Operation / Op Sequence / Job ID /Job Qty 5 B J J A 50 Drill Sharpen Stn Stn Q : What are the Product names? Q : What are the Job names? Q3 : What are the Job Qtys associated with the two Jobs? Q4 : What are the stations? Q5 : What are the operations? Q6 : What are reasonable operation sequence numbers to assign to the two operations? 6 Copyright 05 The evsm Group, All Rights Reserved

165 . Product: Processing, Production & Wait A J4 Drill Sharpen Stn CT= 5 s J3 A A A J J Stn CT= 0 s Q : How long will it take to complete Job 4? Q : What is the production time (Lead ) for A J4? Q3 : What is the wait time for A J4? Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 63

166 3. Station Selection Sharpen Stn CT= 0 s J A J A Drill Stn CT= 5 s Sharpen Stn 3 CT= 5 s Q : What is the minimum processing time for A J? Q : What is the minimum processing time for A J? 64 Copyright 05 The evsm Group, All Rights Reserved

167 4. Station: Processing, Idle J B J A Drill Sharpen Stn Stn CT A = 0 s CT A = 5 s CT B = 0 s CT B = 5 s Q : What are the processing times for Stn and Stn? Q : What is the idle time for Stn? Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 65

168 5. Product: Earliest Release, Start, End, & Production s J B J A Drill Earliest Release = Earliest Release = 0 Stn CT A = s CT B = 4 s Q : What are the Production s for A and B? Q : What are the Start and End s for A and B? 66 Copyright 05 The evsm Group, All Rights Reserved

169 6. Product / Operation / Station: Lot Size 5 A J 3 B J 3 B J3 5 A J4 Drill Stn A: Lot Size = B: Lot Size = CT = 5 s Sharpen Stn A: Lot Size = 0 B: Lot Size = 3 CT = 0 s Q : In what sequence will jobs exit Stn? Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 67

170 7. Product / Station / Operation: Preferred Lot Size 5 A J3 0 B J J A 5 Drill Sharpen A: Preferred Lot Size = (Drill, Stn ) B: Preferred Lot Size = (Drill, Stn ) Stn Stn Q : Would B be processed at all? Q : What Qty of A would be made at the Drill Operation before starting to B? 68 Copyright 05 The evsm Group, All Rights Reserved

171 8. Station: Pre-Start Uptime Stn : Pre-Start Uptime = s Stn : Pre-Start Uptime = 4 s Stn 3: Pre-Start Uptime = 8 s Drill Stn J A CT = s Drill Sharpen Stn 3 CT = 4 s Stn CT = 3 s Q : What route will J take? Q : What will J's Processing be? Q3 : What will J's Wait be? Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 69

172 9. Available Drill Sharpen Stn Stn Stn is used for both Drill and Sharpen. It spends about 50% of its time on each. If the station runs shift, 8 hours, then: Q : What is the station s Available for Drill and Sharpen each day? 70 Copyright 05 The evsm Group, All Rights Reserved

173 0. Activity Drill Stn Available = 4 hrs/day Drill Stn Available = 6 hrs/day Q : What s the total time available for the Drilling operation? Q : How many stations can do drilling? Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 7

174 . Activity Demand Product A Demand 0 Required By () B 40 Q : Both A and B belong to the Scissors value stream. What is the daily demand for this value stream? 7 Copyright 05 The evsm Group, All Rights Reserved

176 3. imum Wait A J Drill Sharpen Stn CT = 5 s Wait = 60 s Stn CT = 0 s Q : How long does J wait after Drill and before any next operation? Q : What is the production time for J? 74 Copyright 05 The evsm Group, All Rights Reserved

177 4. Manual A J Drill Sharpen Stn CT = 5 s Manual = 0 s Stn CT = 0 s Manual = 0 s Q : How many people are required to complete the Drill and Sharpen operations in their? Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 75

178 5. WIP A J Drill 4 A J Sharpen Stn Stn CT = 5 s CT = 0 s Q : What is the Last Operation that J went through? Q : When will J be complete? Q3 : When will J be complete? 76 Copyright 05 The evsm Group, All Rights Reserved

179 6. VSM Generation VS ID = Scissors VS ID = Shears 0 A J 0 A J3 0 B J Drill Stn CT A = 0 CT B = 0 Sharpen Stn CT A = 5 CT B = 0 Required in Shifts / 0 s per shift Q : What percent of time will be used to process A as opposed to B at each of the two stations? Q : What s the daily demand for A and B? Q3 : Extract and draw a VSM for the scissors value stream. Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 77

180 Station: Processing, Idle Click the Open button in the evsm Mix toolbar to open a blank Mix template Open Enter the values for the I_VS worksheet. Note that entering a C in the Comment Row will ensure that row will not be used for any computations "C" for Comment Row End Data A B Product Expected Production Value Stream ID Scissors Scissors 3 Enter the values for the I_Demand worksheet "C" for Comment Row Job Product Job Qty Earliest Release Required By Last Operation End Data J A J B Enter the values for the I_Stn worksheet. Verify the default values for each category. "C" for Comment Row End Data Station Pre-Start Uptime OEE % CT Percent CT Percent / % / % Defaults Stn Stn Shift Warmup Shift 78 Copyright 05 The evsm Group, All Rights Reserved

181 5 Enter the values for the I_Ops worksheet. Make sure to change the units for Manual to. "C" for Comment Row End Data Station Product Operation Op Seq Cycle Qty Per Cycle imum Lot Size Preferred Lot Size imum Post- Op Wait Manual ID ID ID # Stn A Drill Stn A Sharpen Stn B Drill Stn B Sharpen Click the Check button in the evsm Mix toolbar and fix any errors flagged Check 7 This will create the S_Make worksheet Product Expected Production Value Stream ID Op Name Op Sequence ALT:ID ALT:PREF ALT:TRACK Comp ID Comp Qty Workstation imum Lot Size Preferred Lot Size Wait Pre-Start Uptime OEE Shift Shift Duration Manual Rate Per % / A Scissors Drill Stn Shift Sharpen Stn Shift B Scissors Drill Stn Shift Sharpen Stn Shift Copyright 05 The evsm Group, All Rights Reserved Mixed Model Environment 79

182 Using evsm Mix Opens a blank Excel template for inputting your data. Checks input data for any errors and flags them before simulation can run. Runs the simulation of the input data and creates output sheets in the Excel file. Views a summary after the simulation has run for each operation and total summary for the value stream. Creates a production schedule for the various products entered. View production time components. View station time components. Generate value stream map by value stream ID. Floor layout showing summary output from simulation run. 80 Copyright 05 The evsm Group, All Rights Reserved

184 ACME Case Study Plant Introduction You will be using this case study to create a mixed model value stream map. Read through the information below then complete the exercises at the end. Background and Overview ACME, founded in 965, specializes in high-quality surgical instruments and has recently added a family of surgical, re-usable, double-action cutters to its catalog. Each set consists of four cast pieces which are supplied by Tower Hills Foundry. At ACME, the castings are machined, polished, and sent to the final assembly line. Differences in size and finish exist between different cutter types in the family. The metal for the cutter springs is supplied by Fornost Quality steelworks in steel rolls which are cut down into springs and assembled with the castings. One casting set and one spring set makes one final Surgical Cutter. The finished product is individually packaged for shipping to a distributor. Product Family The cutters product family includes three variations: Part# CLP0SR Size: Small Part# CLP0MY Size: Medium Part# CLP03LB Size: Large 8 Copyright 05 The evsm Group, All Rights Reserved

185 Product Manufacturing Flow Springs & Screws Machine (MACH0) Polish (PLSH0) Assemble (ASSM0) Package (PACK0) VSM Job Order List Stations Product CLP0SR CLP0MY CLP03LB Job # Product Job Qty J CLP0SR 36 J CLP0MY J3 CLP03LB J4 CLP0SR 36 J5 CLP0MY J6 CLP03LB The Earliest Release time is 0 days and the Required By time is 3 days. Station Product Operation Op Seq Cycle Qty Per Cycle imum Lot Size Preferred Lot Size imum Post- Op Wait Manual ID ID ID # M SC Red Machine MACH0 CLP0SR Machine MACH0 CLP0MY Machine MACH0 CLP03LB Machine PLSH0 CLP0SR Polish PLSH0 CLP0MY Polish PLSH0 CLP03LB Polish ASSM0 CLP0SR Assembly ASSM0 CLP0MY Assembly ASSM0 CLP03LB Assembly PACK0 CLP0SR Packing PACK0 CLP0MY Packing PACK0 CLP03LB Packing There is one operator per station and the manual time is the same as the cycle time. Copyright 05 The evsm Group, All Rights Reserved ACME Mixed Model Case Study 83

186 Facility Facility runs 5 days a week, shifts per day, 7 production hours per shift. Labor rate runs at 45 per man-hour. Each station has an OEE of 80%. Exercises. Create an evsm Mix spreadsheet for the above.. Confirm that the Production for job J6 is.5 days. 3. Create a value stream map. 4. We have decided to remove the large cutters (CLP03LB) from this product family. Update the spreadsheet to reflect this and draw a new value stream. 5. Create a spaghetti diagram showing the main material flows on a layout page in your evsm Visio file. Display the simulation results on the layout. 6. If the demand doubles, how much time will be needed (no change in resources) to complete production? 7. Which station has the longest wait time? 8. To balance the line better, we have found ways to improve performance at the Assemble operation. All cycle times there are reduced by 50%. How does this impact the production time? 84 Copyright 05 The evsm Group, All Rights Reserved

187 Layout. Create a new page and name it Layout. Turn it into a background page 3. Insert picture of floorplan 4. Open Spaghetti Wizard 5. up Spaghetti Scale 6. Drop a Spaghetti Place icon for each machine in the VS. Use the Machine ID for each name. 7. Click the Layout button in the evsm Mix toolbar Copyright 05 The evsm Group, All Rights Reserved ACME Mixed Model Case Study 85

191 Spaghetti Wizard Tutorial This tutorial will guide you through the steps to generate a spaghetti layout using the Spaghetti Wizard. 0 Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 89

193 Step : Start evsm On your Desktop, click the Start evsm icon. If you see a message like this, you must Enable macros. 4 Click Trust all from publisher to avoid the security notice in future. 3 Click to enable macros. Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 9

195 evsm Help resources are available in the Learn module of the toolbar. Hover over each one to see what they do. 3 Blue icons in the main stencil represent families of shapes. Drag out the Transport icon. 4 Use the shape s right-mouse menus to turn it into a car Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 93

196 Step 3: Initiate the map for the Spaghetti Wizard Click the Open button. Select Spaghetti in the Wizard column and click OK. Open Spaghetti Data The Spaghetti Wizard stencil will open on the left. 3 Drag out the red icon first. This is very important! evsm Data WizSpaghet ti Copyright 05 The evsm Group, All Rights Reserved

198 Step 4: Draw/Import Floor Map Draw or import a floor map. Visio can import most bitmap formats as well as CAD drawings. Either use the Insert tab in Visio or simply copy and paste the picture into a new drawing. Scale evsm Data WizSpaghet ti Copyright 05 The evsm Group, All Rights Reserved

199 0 Drag out a Spaghetti Scale shape and stretch it out to exactly fit a known dimension on the map. The known dimension could be a map scale if available, or a floor dimension you have measured. Enter the actual dimension value on the scale shape by double-clicking it. Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 97

201 Define Activity Centers by dropping a Spaghetti Place icon onto the diagram for each place, then double-clicking each one to name the Place. 0 Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 99

202 Step 6: Draw Spaghetti Paths Any of the line tools in the Drawing toolbar can be used in Visio 003/007 Line tools in Visio 00 In Visio 003/007, the line drawing tools are in the Drawing Toolbar. This can be opened via the right-mouse menus on the Visio Toolbars. In Visio 00, the drawing tools are near the center of the "Home" ribbon. evsm Data WizSpaghet ti Copyright 05 The evsm Group, All Rights Reserved

203 Use the Visio line drawing tools to map the paths. You must ensure that each path starts and ends in a Spaghetti Place icon. You can set color and line thickness of the paths using standard Visio formatting. 0 Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 0

205 Click the Solve button. evsm will create a spreadsheet report of the paths. Note that the Solve button recreates the Excel report, it DOES NOT update it. Solve 0 Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 03

207 evsm Data WizStandard Work Standard Work Wizard Tutorial This tutorial will guide you through the steps to generate a standard work chart using the Standard Work Wizard. A000 Walk 5 Sec A0060 Walk 0 Sec 7 Operator Balance Chart A000 all Demand 6 Demand 75 Server Resource Takt 6.40 Walk Sec A0030 Take Order Machine 0 Manual Manual 0 Wait Batch Size Maker Resource Takt 6.40 Walk Sec A0070 Prep Lemons Machine 0 Manual Manual 0 Wait Batch Size A000 A0060 Resource Takt Resource Legend Takt 6.40 Z000 all SWCS Summary FTE.3 Staff Server Maker Walk 5 Sec A0040 Pick Lemons for Prep Machine Manual Manual Wait Walk Sec A0080 Start Juicer Machine.5 Manual 0.5 Manual.5 Wait Server : A000 Take Order : A0030 Pick Lemons for Pre.. : A0040 Standard Work Chart Batch Size Batch Size Deliver to Customer : A0050 Maker : A0060 Eff Act Takt Sec A0050 Deliver to Customer Machine Manual Manual Wait Batch Size A0090 Unload Juicer Machine 0 Manual 0.75 Manual 0 Wait Batch Size Prep Lemons : A0070 Start Juicer : A0080 Unload Juicer : A Resource Eff Machine Eff Manual Wait Eff Manual Upstream Walk Legend Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 05

208 Step : Start evsm On your Desktop, click the Start evsm icon. If you see a message like this, you must Enable macros. 4 Click Trust all from publisher to avoid the security notice in future. 3 Click to enable macros. 06 Copyright 05 The evsm Group, All Rights Reserved

211 evsm Help resources are available in the Learn module of the toolbar. Hover over each one to see what they do. 3 Blue icons in the main stencil represent families of shapes. Drag out the Transport icon. 4 Use the shape s right-mouse menus to turn it into a car Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 09

212 Step 3: Initiate the map Standard Work Wizard Click the Open button. Select Standard Work in the Wizard column and click OK. Open StandardWork Data The Standard Work Wizard stencil will open on the left. Customer Center 3 Drag out the red icons first. This is very important! 4 Enter the amount of hours per day. evsm Data WizStandard Work Sec 0 Copyright 05 The evsm Group, All Rights Reserved

214 Step 4: Draw the Flow Complete as shown below, including annotation and data values. A000 A00 Resource Takt Server A000 Take Order Resource Takt Maker A0050 Prep Lemons Activity Center Machine Manual Manual Wait Batch Size Do not change any of the fields. These will calculated later. Machine Manual Manual Wait Batch Size 0 0 Resource Center The green shapes are called Centers. Use the centers to represent the flow. A0030 Pick Lemons for Prep Machine Manual Manual Wait Batch Size A0060 Start Juicer Machine Manual Manual Wait Batch Size A0040 Deliver to Customer A0070 Unload Juicer Machine Manual Manual Wait Machine Manual Manual Wait evsm Data WizStandard Work Batch Size Batch Size Sec Copyright 05 The evsm Group, All Rights Reserved

216 Step 5: Sequence Arrows Click the Sequence button to add sequence arrows. Sequence A000 A00 A Resource Takt Server A000 B Take Order Resource Takt Maker A0050 Prep Lemons Machine Manual Manual Wait 0 0 Machine Manual Manual Wait 0 0 Hold down the SHIFT key and select the centers in the order shown here. This is the sequence in which the server will perform their tasks. Do NOT connect a sequence arrow from the last task back to the server Batch Size A0030 Pick Lemons for Prep Machine Manual Manual Wait C Batch Size A0060 Start Juicer Machine Manual Manual Wait Batch Size Batch Size A0040 Deliver to Customer D A0070 Unload Juicer Machine Manual Manual Wait Machine Manual Manual Wait evsm Data WizStandard Work Batch Size Batch Size Sec 4 Copyright 05 The evsm Group, All Rights Reserved

218 Step 6: Sequence Arrows Part A000 Walk 5 Sec A00 A Resource Takt Server A000 Take Order Resource Takt Maker A0050 B Prep Lemons Walk Sequence arrows have been added with data on it as well. Enter the Walk from each center. Double-click the unit to change it from to Sec. Sec Machine Manual Manual Wait Batch Size A Pick Lemons for Prep Hold down the SHIFT key and select the centers in the order shown here for the second resource and associated set of activities. Machine Manual Manual Wait Batch Size A0060 C 0 0 Start Juicer Walk 5 Sec Machine Manual Manual Wait Machine Manual Manual Wait Batch Size Batch Size A0040 Deliver to Customer A0070 D Unload Juicer Machine Manual Manual Wait Machine Manual Manual Wait evsm Data WizStandard Work Batch Size Batch Size Sec 6 Copyright 05 The evsm Group, All Rights Reserved

220 Step 7: Perform Calculations A000 Walk 5 Sec A0060 Walk 0 Sec Resource Takt Server A0030 Take Order Resource Takt Maker A0070 Prep Lemons Walk Sec Machine Manual Manual Wait Batch Size 0 0 Walk Sec Machine Manual Manual Wait Batch Size 0 0 Fill in the remaining Walk s. A0040 Pick Lemons for Prep A0080 Start Juicer SWCS Summary Walk 5 Sec Machine Manual Manual Wait Walk Sec Machine Manual Manual Wait Batch Size Batch Size A0050 Deliver to Customer A0090 Unload Juicer Machine Manual Manual Wait Machine Manual Manual Wait evsm Data WizStandard Work Batch Size Batch Size Sec 8 Copyright 05 The evsm Group, All Rights Reserved

221 Click the Path button and the Tag button to create path numbers and tags for each resource. 4 Click the Solve button in the toolbar. Solve A000 all Path Tag This is a critical step to get the standard work chart to plot in the correct order 3 Drag out the Summary Center Demand Demand 75 Takt Z000 SWCS Summary all FTE Staff Copyright 05 The evsm Group, All Rights Reserved evsm Wizards 9

222 Step 8: Visualize with Charts A000 Walk 5 Sec A0060 Walk 0 Sec Resource Takt Server 6.40 A0030 Take Order Resource Takt Maker 6.40 A0070 Prep Lemons Walk Sec Machine Manual Manual Wait Batch Size 0 0 Walk Sec Machine Manual Manual Wait Batch Size 0 0 A0040 Pick Lemons for Prep A0080 Start Juicer Walk 5 Sec Machine Manual Manual Wait Walk Sec Machine Manual Manual Wait Batch Size Batch Size A0050 Deliver to Customer A0090 Unload Juicer Machine Manual Manual Wait Machine Manual Manual Wait evsm Data WizStandard Work Batch Size Batch Size Sec 0 Copyright 05 The evsm Group, All Rights Reserved