What do you understand by Value Stream Mapping? 1(a) (b) What are the types of V

Question

What do you understand by Value Stream Mapping? 1(a) (b) What are the types of Value Stream Mapping (c) Give an example of each type of Value Stream Mapping 2(a) Name six elements that a company which wants to be successful in lear manufacturing.philosophy must incorporate in the operation of their business. (b) Briefly explain the importance of each of the elements you stated in a successful operation of lean (c) State at least one technique employed in lean manufacturing during balancing work in an assemblyline. 3. The start-up company has signed a contract to ship 850,000 pairs of shoes to a customer within the first six months of 2016. The factory has been set up to operate a two 9-hour shifts per day, and not to work on Saturdays and Sundays There is an allowance of 45 minutes total per shift for employee breaks, and a 10 minutes shut down per shift for minor maintenance actions on the machines. Calculate the rate at which the company must produce each pair of shoes to satisfy the customer's demand. Calculate Takt time Show all your calculations

Explanation / Answer

2A. Elements in Lean Manufacturing philosophy.

i. Setup time reduction

ii. Kanban

iii. Total productive Maintainance

iv. Poka yoke

v. Cellular layout

vi. Kaizen

2B.

i. Setup time reduction:

The lean manufacturing focused on minimisation of setup time and change over time because these two consumes more work time and reduces the proper usage of resources ie machine and operator time. to over come this problem a sequencial and structural work instructions are provided to perform job. The operator will follow the instructions what we gived and complete the job or work within time.

ii. Kanban

Itis a shop floor control tool which shares the customer requirement information from bottom lever worker to top level worker. The product is completed all inspection process it sends to finished goods. After that it is withdrawn from finished goods against customer requirements to Stock up the moved quantity it is replaced with a coloured card electonically. It will become a production order in internal streams.

iii. Total productive Maintainance

It Assist basic preventative maintenance of job to workers selfly, So that any break down time of machines reduced. it is also improve operational efficiency of machine by worker does tightening, lubricating,clening, inspecting activity of machine.

iv. Poka yoke

It means mistake proofing. It involves in a system to eliminate human mistakes in the field of quality, safety and other process parameters to ensure quality and safety in the manufacturing lines

v. Cellular layout

In this layout machines and workstations are arreanged ina large number of small cells connected tightly in many stages sothat all stages of process can compelte with in a single cell or in series of cells.It helps to many non valuve added activities from production processes ie waiting times,transport, bottle necks, work in process.

vi. Kaizen

Which means a small improvement. to maintain continual improvement activities throughout the organisation this culture should be created and maintained. Kaizen is mainly focused on operators for improvement in work conditions,safety, quality,setup time reduction etc.

2C.

Continuous Improvement is a one of the technique used in Lean maufacturing

The name it self says improves continuously by following some set of rules and guidlines. it is also called as Rapid improvement,it helps streamline all the workflows with in the working environment. It follows a Proceeding cycle or pdca cycle which compraises of 4 phases in process. They are

a. Plan: In this phase identified any change required and planing for change in the syt.

b. Do: once the planning is over then it is exicuted.

c. Check: Data is collected and viewed to check the sucess of change

d. Act: once the changes is determined to be sucess then the plan is implemented on total system.

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