Lean Tools WCG VSP Master

Instructions
Sheet
Data Entry
Item
1
2
3
4
5
6
7
8
9
TAKT
1
2
3
4
5
6
7
8
9
WC Chart
Comment
Fill in the Orange cells in the "Lean Line Characteristics" Table.
Enter the Operation name in the Grey Boxes and the Headcount for that operation in the Orange box beside.
Enter the Job elements and Assign the time to the correct category
For a description of the use of each time classification, hold the mouse over the column title to reveal the description comment
When entering "Batch" time, enter the total time taken, this will be divided by the Batch size automatically.
Under Question "Is this Value or Non-Value Added?" type "n" (Non Value Added) or "v" (Value Added) as appropriate.
You may add or delete rows as required but always ensure to add or delete a full row and not just specific cells. Highlight a full row by
clicking on the Row Header (The number on the LHS of the page).
When balancing lines you may move elements between operations. When moving an element, highlight every cell from the Job Element
Name to the "n" or "v" designation, drag all 10 cells and drop them in the desired location.
If using the Value added / Non-Value added calculation it will be necessary to click the "Refresh" button after moving job elements
around. This will ensure the formulae attached to these cells are not affected by the move.
Complete Steps 1, 2 & 3 to calculate the Total Available Production Time.
Step 1 will usually only be required to be done once per line (as the graph is completed for the first time)
Steps 2 & 3 should be altered on a monthly basis.
There are 2 Options modes when calculating your TAKT, Constant TAKT and Variable TAKT. Click the appropriate button to toggle
between the two.
In Constant TAKT mode, the takt time for each operation is the same. In Variable TAKT mode, a different takt time can be entered for
each operation in the space provided.
Constant TAKT:
Figures for TAKT and Calculated TAKT (as defined on the TAKT sheet) are generated automatically form the information provided in
Sections 1, 2 & 3.
There is an additional option to add a Temporary TAKT time line to cover any extraordinary events on the line. This value is simply
added manually by the user.
Variable TAKT:
Both TAKT and Temporary TAKT figures must be added manually for each of the operations.
VIP
Complete Step V to Indicate wether or not VIP Projects have been identified and resourced. Answer "Yes" or "No" in the drop down
menu
The Utilisation by Operation figures are shown underneath the graph. This section is not printed with the rest of the graph.
VSP
1
2
Use the buttons to insert the required object. The objects will always appear at a default size and location.
Click and drag the object to the desired location. Orientate, re-size and re-name the object as appropriate.
Quick Reference Guide to Definitions, Formulae & Assumptions

Sheet
Data Entry
TAKT
Item Name
Comment
Batch Time
Any Non-repetitive tasks performed by the operator. Eg. SFP interaction.
Note: For the purpose of this tool, a 'Batch' is the term given to a Production Order or a Lot
All Manual Time
Only used if there are no machine based tasks in the operation.
Manual Before M/C
Tasks carried out up to and including the loading of a machine.
Tasks carried out during the machine cycle, sometimes even work on the next unit (Used to prevent Forced Idle
time)
Manual During M/C
Manual After M/C
Any work carried out from unloading the m/c to the end of the operation inclusive.
The time taken by the operator to manually load the machine (Note: This is a duplicate entry. This time has
Manual Load Machine
already been included in the Manual Before M/C column)
Machine Cycle (M/C)
The repetive cycle time. Often includes several stages, eg. A Heating and a Cooling phase.
The time taken by the operator to manually unload the machine (Note: This is a duplicate entry. This time has
already been included in the Manual After M/C cycle column)
Manual Unload Machine
Note: Additional information on above items available in comment form on Data Entry sheet
Headcount (Smiley Face) The number of people performing the exact same operation per line, i.e. Parallel or Duplicate Work Stations
Available Time (Hours)
The total time available for production per month.
Maximum Allowable WIP
Sum total of all WIP which can be at each station, in all IPK's and stored before or after the line.
Throughput Time
The time to process a complete customer order.
TAKT
Calculated TAKT
Temporary TAKT
Gross Time per Shift
Other Deductions
Line Structure
The text book definition, i.e. Total Available Work Time / Customer Demand
Total Available Work Time / Yielded Starts
An override option, to be used when a non-standard TAKT must be used on the line for a short period.
Total time an operator is in on-site, i.e. including paid and unpaid breaks.
Non-Break activities which take from the total available time. Eg. Team Meetings etc.
Enter the number of Parallel (Duplicate) lines operating on a shift.
Average Actual Units per

Hour
Design Units per Hour
WC Chart
Flow Line
% Balance to TAKT
% Balance to Constraint
% Performance
Actual units per hour using standard staffing levels as per WCG and VSP averaged over a recommended period
of one week.
The number of units the line is required to produce per hour in order to meet customer demand
Shows the true rate at which a unit passes through an operation, i.e. Takes headcount into account. Note: The
line ignores non repetitive (Batch) time. Station Processing Time / Headcount
(Total Cycle Time - Forced Idle Time) / Headcount X TAKT.A measure of how utilized the line is realtive to the
monthly demand.
(Total Cycle Time - Forced Idle Time) / Headcount X ConstraintA measure of labor utilization relative to the
constraint. Note: Cannot be calculated for Variable TAKT option as key parameters (eg. Demand, Yield, Available
Time) are not uniform throughout the line.
Average Actual Units per Hour / Expected Design Number of Units per Hour
% Overall Line Effectiveness % Balance to Takt X % Performance

% Balance to Takt & %
Performance Colour Coding
Manual Time
Load/Unload Time
Forced Idle Time
Total Cycle Time
VSP
Quick Train Station

Highest Cycle Time
Lowest Cycle Time
Highest Criticality
The Colour Coding in the % Balance to Takt and the % Performance metrics is used to identify whether VIP
Projects associated with these metrics have been identified and resourced.
Total PB Touch Time, including loading and unloading time.
For reference only. Not included in Total Cycle Time calculation as it is included in Manual Time
Time spent waiting for a m/c operation to finish
Manual Time (including Load/Unload) + Forced Idle Time
Quickest Train Station
Refer to WC Graph.
Refer to WC Graph.
As assessed by QA Dept. e.g. Ref. FMEA
Lean Line Characteristics

Line Name
Batch
Size
No. of PB's
per Shift
Maximum
Allowable
WIP
Thru'put
Time
(Days)
Available
Time
(Hours)
TAKT
Time
(Secs)
Hemashield Graft Cell - Training Version
31
10
200
0.84
0.00
#DIV/0!
Job Elements
Batch
All Manual
Manual
Before
M/C
No
Operation
Stain Inspection
Stain Inspection
Mechanical Peel
Check overall Graft Length

Check Graft OD
Check Graft ID
30.00
Sub Totals
Mechanical Peel Testing (Blister Trays)
Primary Inspection
Primary Inspection
Label Verification
Primary Inspection
Count & Verify
Fill in Labels
Air Testing
Sub Totals
Inner Blister Seal
0.00
30.00
9.00
20.00
21.00
0.00
0.00
0.00
0.00
0.00
0.00
70.00
50.00
78.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
78.00
88.00
0.00
0.00
0.00
0.00
0.00
0.00
88.00
0.00
0.00
0.00
0.00
0.00
0.00
70.00
Sub Totals
3
15.00
15.00
Sub Totals
Calibrate Airtester
Validate/Authorize necessary SFP's (paperwork)
Clamp graft and start air tester
Air test graft
Remove graft from air tester
Cut to length and place into tray
30.00
38.00
13.00
Sub Totals
51.00
60.00
Verify quantity, batch, SFP & labels

Load sealer with blister and push in
Seal blister
Manual
Manual Machine Manual
Manual
During
Load
Cycle
Unload
After M/C
M/C
Machine (M/C) Machine
9.00
9.00
36.00
2.50
14.00
0.00
9.00
0.00
16.50
2.50
9.00
36.00
2.50
No
Operation
Job Elements
Batch
All Manual
Manual
Before
M/C
Manual
Manual
During
Load
Cycle
Unload
After M/C
M/C
Pull out and remove sealed blister

Get sealed blister and inspect for sealing defects
Place label onto inner blister tyvek
Move inner blister to the next station
Outer Blister Sealing
Final Packaging
10
11
8.63
7.13
1.08
Sub Totals
Count and Verify Labels
Blow outer blister in HEPA Clean 2000
Place inner blister into outer blister
Place outer blister into seal nest
Place outer tyvek lid on outer blister
Slide seal nest into Belco
Seal blister
Slide seal nest out from Belco
Remove sealed outer blister from seal nest
Get sealed blister and inspect for sealing defects
Place label onto outer blister tyvek
60.00
50.00
Sub Totals
50.00
30.00
0.00
30.00
11.00
3.00
24.00
8.00
9.00
4.00
Sub Totals
30.00
30.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Final Pack & Inspection
0.00
0.00
0.00
16.84
0.00
3.00
0.00
0.00
3.00
3.00
3.00
2.00
3.00
3.00
2.00
3.00
6.00
3.00
1.00
15.00
5.00
3.00
1.00
No
Operation
Batch
All Manual
Manual
Before
M/C
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Job Elements
12
13
14
15
16
Manual
Manual
During
Load
Cycle
Unload
After M/C
M/C
No
Operation
Batch
All Manual
Manual
Before
M/C
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Sub Totals
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Job Elements
17
18
19
20
Manual
Manual
During
Load
Cycle
Unload
After M/C
M/C
Total Value Added Work:

0.00
Total Non-Value Added30.00
Work:
0.0%
100.0%
1
Check Here to Display VA & NVA percentage's on the Graph
Lean Line TAKT Time Calculation

Is the TAKT time?
Constant TAKT
Step I: Available Minutes for Production per Shift

Notes:
1. Fill in the Appropriate information for up to 3 different Shifts per day below.
2. In the case where the plant runs a 4.5 Day week, use the Third shift option for Fridays details.
Total Available Time per First Shift

Total Available Time per Second Shift
Minutes
0
Standard Deductions
Paid Breaks
Unpaid Breaks

Standard Deductions
Paid Breaks
Unpaid Breaks
0
0
Other Deductions
Total Available Time per Third Shift
Minutes
0

Standard Deductions
Paid Breaks
Unpaid Breaks
0
0
Other Deductions
Net Available Time/Shift
Step V: VIP
Enter the No. of "First" Shifts this Month

Enter the No. of "Second" Shifts this Month
Enter the No. of "Third" Shifts this Month
0
0
VIP Description
VIP Identified & Resourced
% Balance to Takt
No
% Performance
No
Step III. Line Demand, Yield & Structure Information

Demand =
Yield =
Starts =
0
0%
#DIV/0!
units/month
%
units
0
#DIV/0!
Average Actual Units per Hour

Design Units per Hour
Line Structure
First Shift:
Second Shift:
Third Shift:
0
0
0
Based on the information entered above, the Total Time available for production this month is:
line(s)
line(s)
line(s)
Minutes
Step IV: Constant TAKT Time Calculation:

TAKT Time =
0
0
Other Deductions
Step II: Shift details for the Month
Minutes
0
Total Available Production Time

Customer Demand
#DIV/0!
secs/unit
Calculated TAKT Time =
Total Available Production Time

No. of Starts Required
#DIV/0!
secs/unit
Temporary TAKT Time =

(Manually Entered)
Any value to which the line must produce, for a short

period, due to extraordinary circumstances
secs/unit
Copyrighted by Boston Scientific
Work Content Graph
Takt Time
#DIV/0!
100
Seconds
% Balance to
Takt
90
TAKT
80
Calculated TAKT
Flow Line
70
Operator
Time (Secs)
Temporary TAKT
Batch Time Per
Unit
#DIV/0!
Load/Unload
Machine
60
50
% Balance to
Constraint
40
#DIV/0!
30
20
% Performance
10
#DIV/0!
Machine Cycle
Final Packaging
Outer Blister
Sealing
Inner Blister Seal
Air Testing
Label Verifcation
Primary Inspection
Mechanical Peel
X0
Stain Inspection
Downtime
Manual Time
30
50
78
88
26
17
38
30
Load/Unload Time
12
12
12
Batch Time Per Unit
Forced Idle Time (Wait

for machine)
36
Batch Size
31
Units
% Overall Line
Effectiveness
#DIV/0!
0
Total Cycle Time
30
50
78
88
62
17
44
30
398
Revision Date:

No. of PB's per
Shift
Max
Allowable
WIP (ea)
31
10
200
Thru' put Time

Available
(Days)
Time (Hours)
0.84
0.00
Stain
Inspection
Mechanical
Peel
Demand
Yield
#DIV/0!
0%
1
0
TAKT
(secs)
Final
Pack
Batch Size
Outer
Blister Seal
Primary
Inspection
Primary
Inspection
9
Inner
Blister Seal
5
Label
Verification
Quick Train Station ( shift or less)

Highest Cycle Time
Lowest Cycle Time (<60% Takt)
Highest Criticality
Label
Verification
Material Flow
Standard WIP (Units)
Standard WIP (Batches)
Product Builder
Copyrighted by Boston Scientific
Operation Time Summary Sheet
Line Name
Batch Size
No. of PB's per

Shift
Maximum
Allowable WIP
Thru'put Time
Available
Time (Hours)
31
10
200
0.84
0.00
Machine
Cycle
Manual
Unload
Machine
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
16.50
9.00
0.00
16.84
0.00
11.00
3.00
24.00
0.00
0.00
0.00
0.00
0.00
0.00
#DIV/0!
0.00
0.00
#DIV/0!
0.00
0.00
#DIV/0!
0.00
#DIV/0!
0.00
14
#DIV/0!
15
#DIV/0!
16
17
18
19
20
Operation Description
Takt
All Manual
Manual Before
M/C
Stain Inspection
#DIV/0!
30.00
0.00
0.00
0.00
Mechanical Peel
#DIV/0!
50.00
0.00
0.00
0.00
Primary Inspection
#DIV/0!
78.00
0.00
0.00
Label Verification
#DIV/0!
88.00
0.00
0.00
Air Testing
#DIV/0!
0.00
9.00
Inner Blister Seal
#DIV/0!
0.00
0.00
Outer Blister Sealing
#DIV/0!
0.00
Final Packaging
#DIV/0!
30.00
#DIV/0!
10
11
12
13
No
Manual During
Manual Load
Manual After M/C
M/C
Machine
Batch Time
Downtime
0.00
0.00
0%
0.00
70.00
0%
0.00
0.00
0%
0.00
30.00
0%
36.00
2.50
51.00
0%
0.00
0.00
60.00
0%
8.00
9.00
4.00
50.00
0%
0.00
0.00
0.00
30.00
0%
0.00
0.00
0.00
0.00
0.00
0%
0.00
0.00
0.00
0.00
0.00
0.00
0%
0.00
0.00
0.00
0.00
0.00
0.00
0%
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%
#DIV/0!
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%
#DIV/0!
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%
#DIV/0!
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%
#DIV/0!
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%
#DIV/0!
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0%

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Instructions

Quick Reference Guide to Definitions, Formulae & Assumptions

Average Actual Units per

% Overall Line Effectiveness % Balance to Takt X % Performance

Quick Train Station

Lean Line Characteristics

Hemashield Graft Cell - Training Version

Check overall Graft Length

Mechanical Peel Testing (Blister Trays)

Inner Blister Seal

Verify quantity, batch, SFP & labels

Pull out and remove sealed blister

Outer Blister Sealing

Final Pack & Inspection

Total Value Added Work:

Lean Line TAKT Time Calculation

Step I: Available Minutes for Production per Shift

Total Available Time per First Shift

Total Available Time per Second Shift

Gross Time per Shift

Total Available Time per Third Shift

Gross Time per Shift

Net Available Time/Shift

Net Available Time/Shift

Enter the No. of "First" Shifts this Month

VIP Identified & Resourced

Step III. Line Demand, Yield & Structure Information

Average Actual Units per Hour

Step IV: Constant TAKT Time Calculation:

Net Available Time/Shift

Step II: Shift details for the Month

Total Available Production Time

Calculated TAKT Time =

Total Available Production Time

Temporary TAKT Time =

Any value to which the line must produce, for a short

Copyrighted by Boston Scientific

Work Content Graph

Hemashield Graft Cell - Training Version

Inner Blister Seal

Batch Time Per Unit

Forced Idle Time (Wait

Hemashield Graft Cell - Training Version

Thru' put Time

Quick Train Station ( shift or less)

Copyrighted by Boston Scientific

Operation Time Summary Sheet

No. of PB's per

Hemashield Graft Cell - Training Version

Inner Blister Seal

Outer Blister Sealing

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