Aylesbury Pressings

What improvements should the management team at Aylesbury pressings be pursuing and why?

Aylesbury pressings classic lean sustainability

After the first flush of improvements and lean thinking many companies lose focus. Need to return to lean principles:
1.
2. 3.

4.
5.

Understand customer Understand the value streams Make value flow Pull at the customers rate of demand Seek perfection

Understand the value stream Value Stream Mapping

A key tool is the Value Stream Map (VSM) Complete the value stream map and calculate the % of value added to nonvalue added time for a steering bracket Need to know ; TAKT = Available time demand

VSM
Guide to Icons
Manual Information flow
Electronic Information Flow Steel supplier Blanking Outside source Internal process For full VSM workbook see Learning to See by Rother and Shook 13 Inventory Finished goods to customer Push flow

C/O= 15 min Information Box

C/T= 0.2s
v/a= 0.2s

Change over time Cycle time Value added

Calculate Value added /total time for a steering bracket

Calculate the TAKT Calculate the queue times for each of the piles of inventory Add in cycle time for each VA stage (assume 60s for assembly)

Calculate TAKT
Demand = 170/day Time available = assume 2 shifts of 7 hrs each Takt = 840/170 = 4.94 min say 5 min

% VA to NVA
VA = 0.2+2+60 +180+60 = 302.2s = 5min 2.2s NVA = 2500+1000+10370+1620+3115 = 18605 min % VA to NVA = (5/18605) x 100 = 0.027% Comment this is tiny the equivalent of 34s work in a working week of 35 hours

VSM current state Steel supplier

Monthly forecast Weekly orders Production Control MRP II

Six monthly and monthly forecasts Weekly requirement

Customer

Daily call off

weekly schedule

Daily schedule 500 dispatch 623 Paint 324

C/O= zero C/T= 90min v/a= 3 min 1620 min 0 min

Blanking 200
C/O= 15 min

Press
C/O=30 min C/T= 2s

1780 35 13 Ass nil 230 16

C/O= 5 min C/T= 60s v/a=

Final ass

nil
C/O= zero C/T= 1 min v/a= 3115 min

C/T= 0.2s
v/a= 0.2s 2500 min 0.2s 1000 min

v/a= 10370 min

2s

60s

180s

60s

Monthly forecast Steel supplier Weekly orders Production Control MRP II

Six monthly and monthly forecasts Weekly requirement

Customer

Daily call off

weekly schedule

Daily schedule despatch

Blanking
C/O=

Press
C/O= C/T=

Ass
C/O= C/T= 60s v/a=

Paint
C/O= C/T= v/a=

Final ass
C/O= C/T= v/a=

C/T=
v/a=

v/a=