Page 154 - How To Implement Lean Manufacturing

132 Cha pte r Se v e n

QED Motors Future State Production
Planning
(local)

Note the significant change
Value Stream Summary Note Planning Changes…
in the process lead time….
Total Lead Time 20.38 Hrs From 210 hrs to 20 hrs!!! 1-2 day delay eliminated
2-Shipping schedule sent to storehouse only
Total Processing 0.98 Hrs 3-Production triggering and leveling done by
Time kanban
2x/Shift
Takt Time 7.09 Min 4-Wire coil supply to the Coil Insertion cell is
now done by a kanban pull system
5-Heijunka board at Coil Insertion is updated
twice per shift and model mix leveled
Note Process Changes
1-Production is balanced at 50/50 mix
2-Press and Hipot are combined for better process
Coil Wind balance
3-ProcessWIP hasinvnentorylimits and
segregations to synchronize flow, Polish process is
CT 4.5 Min eliminated
4-CNC lathe, old bottleneck at 9 min. Now has 6.5
CO 6 Min
min cycle time, CO reduced from 45 to 11 minutes
Operators 3 Stf
Stator Prep Coil Insertion Lace Press & HiPot Preheat Varnish
CT Lg 6.5 Min Max CT Lg 13.5 Min Max CT 5.7 Min Max CT 6 Min Max CT 90 Min Max CT 40 Min
6 Unt 5 Unt 4 Unt 24 Unt Batch 27 Unt Batch
CT Sml 6 Min Cell Lg 2 Unt Operators 5 Stf Scrap 3.2 % 18 Unt 9 Unt
Size Size
CT 6.25 Min CT Sml 13.0 Min Operators 1 Stf Operators 1 Stf Operators 0 Stf
Operators 2 Stf Cell Sml 2 Unt
CT 6.61 Min
Operators 14 Stf

112 Min 46 Min 30 Min 165 Min 120 Min
6.25 Min 6.61 Min 5.70 Min 6.00 Min 5.00 Min 4.44 Min
Mths Days Shifts Hrs
21.5 2 9.75 60
Days Shifts Hrs Min
Drawn in: eVSM Software (www.evsm.com)

FIGURE 7-10 Future state value stream map, QED motors.