Future State Map For Current State Map

Future State Map For Current State Map
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Future State Map For Current State Map
Current State Analysis
The current production lead time of 23.5 days is too high and needs to be reduced by more than 50%. The current production is associated with high inventory where coils are stored and moved for only two days in a week that is Tuesday and Thursday. The products also stay for 4.5 days before they are shipped. There is a need to reduce inventory by ensuring the right amounts of raw materials and finished products are in movement. The current state map shows that the processes receive information from the production control which is a push system.
Lean manufacturing requires the information to flow the other way also referred to as a pull system. A better approach is to use the Toyota system where the production processes dictate the schedule as opposed to the production control (“Value Stream Mapping,” n.d). There is also a tremendous amount of work in progress where a single product takes. It accumulates at each machine and processes for welding and assembly. The sequencing of workflow and production is not clearly defined. Also, the change over time of 1 hour in the stamping process is too high. The overall uptime of the machine and processes also shows limited efficiency, especially for welding.
Improvements/Future State
The future state map should be able to adopt lean manufacturing strategies. The new state map will have a lower lead time, at least 7 days.

The time between material release and the final product needs to be shortened. Tools like Kanban are used to reduce lead time and optimize production quantities (“Value Stream Mapping,” n.d). Customers will wait for fewer days for their finished products. This is achieved by removing steps which do not add value like travel time, work in progress inventory, reworking, material waste, and additional inspections. The machines will be grouped according to functions not according to products. Reducing the work in progress and inventory improves flow and allows the company to handle smaller quantities.

Figure 1. Future state map

Reference
Value Stream Mapping. (n.d).