Lean Manufacturing 310EMM

Value Stream Mapping

Pressco Production Data
The Pressco Company produces several components for vehicle assembly plants. This case
concerns one product family, a steel instrument-panel bracket sub-assembly in two types: one
each for left hand and right hand drive versions of the same vehicle. These components are sent
to the assembly plant of the customer.
.

PRODUCTION PROCESS
Pressco processes for this product family involve blanking and piercing and forming metal part
from steel coil, followed by welding and subsequent assembly. The components are then
palletised and despatched to the vehicle assembly plant on a daily basis.

 Switching between Type 'LH' (left hand drive) and Type 'RH' (right hand drive) brackets
requires a 1-hour changeover in blank & pierce and a 10-minute fixture change in the welding
processes.

 Steel coils arrive from the supplier on Tuesdays and Thursdays.

CUSTOMER REQUIREMENTS

 9,200 pieces per month

-6,000 per month of Type 'LH'
-3,200 per month of Type 'RH'

 The products are packed onto partitioned trays with 20 brackets per tray and 10 trays per
pallet. The customer orders in multiples of trays.

 One daily shipment to the assembly plant by road.

WORK TIME

 20 days in a month
 8.5hours per day
 Two 10 minute breaks and a 30min lunch break per day
 Manual processes stop during breaks

PRESSCO PRODUCTION CONTROL DEPARTMENT

 Receives customer’s 30 day forecasts and enters them to MRP

 Issues Pressco’s 3 week forecast to steel supplier via MRP
 Secures coil steel by weekly email to steel supplier
 Receives daily firm order from customer

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 Generates MRP based weekly departmental requirements based upon customer order, WIP
inventory levels, F/G inventory levels, and anticipated scrap and downtime
 Issues weekly build schedules to laser cut, welding and assembly processes
 Issues daily shipping schedule to Despatch Department

PROCESS INFORMATION

All processes occur in the following order and each piece goes through all processes.

BLANK & PIERCE

This process is used for the majority of Pressco parts.

Cycle Time: 1 second (60 pieces per minute)

- Changeover Time: 1 hour (good piece to good piece)
- Machine Reliability: 85%
- Observed Inventory:
- 5 days of coils before stamping
- 2.300 pieces of Type 'LH' finished stampings
- 1,200 pieces of Type 'RH' finished stampings

SPOT WELD WORKSTATION I

(Dedicated to this product family)

Manual process with one operator

- Cycle Time: 39 second - Changeover Time: 10 minutes (fixture change)

- Machine Reliability: 100%
- Observed Inventory:
- 550 pieces of Type 'LH'
- 300 pieces of Type 'RH'

SPOT WELD WORKSTATION II

(Dedicated to this product family)

Manual process with one operator

- Cycle Time: 46 second

- Changeover Time: 10 minutes (fixture change)
- Machine Reliability: 80%
- Observed Inventory:
- 800 pieces of Type 'LH'
- 400 pieces of Type 'RH'

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ASSEMBLY WORKSTATION I
(Dedicated to this product family)

Manual process with one operator

- Cycle Time: 62 second

- Changeover Time: none
- Machine Reliability: 100%
- Observed Inventory:
- 600 pieces of Type 'LH'
- 320 pieces of Type 'RH'

ASSEMBLY WORKSTATION II
(Dedicated to this product family)

Manual process with one operator

- Cycle Time: 40 second

- Changeover Time: none
- Machine Reliability: 100%
- Observed Finished Goods Inventory in Warehouse:
- 1250 pieces of Type 'LH'
- 720 pieces of Type 'RH'

DESPATCH DEPARTMENT

Remove parts from finished goods warehouse and packs them for
road delivery to customer.

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Welded parts
store
Blank & Spot-weld 1
Steel coil Despatch
pierce
store area
WIP
Spot-weld 2

Finished
goods
Assembly 1 Assembly 2 storage
area

Blank & pierce Final

presses inspection

Pressco Factory Floor Layout

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