Value stream mapping for the process industries : creating a roadmap for lean transformation /: creating a roadmap for lean transformation. (2015)

• Record Type: Book
• Further Information: Note: Peter L. King, Jennifer S. King.
• Authors: King, Peter L; King, Jennifer S, 1980-
• Contents: The Value of Mapping; A Focus on Flow Rather Than on Function; Summary; ; Value Stream Mapping Fundamentals ; Introduction to Value Stream Mapping; Material Flow; Major Process Steps; Data Boxes; Process Box and Process Data Box; Inventory Data Box; Transportation Data Box; Customers Data Box; Supplier Data Box; Material and Information Flow Icons; Information Flow; The Third VSM Component—The Timeline; Parallel Equipment; Level of Detail; Summary; ; VSM Enhancements for Process Operations; Distinguishing Features of Process Operations That Require a Different VSM Approach; Capital Intensive vs. Labor Intensive; Material Flow Patterns—SKU Fan Out; Product Changeover Issues Are Complex; Product Families—Selecting a Target Product or Family; Takt Rate vs. Takt Time; Units of Production; Generating the Map; Time Units; Where to Begin; Summary; ; Additional Good Mapping Practices; Good VSM Practices; Map Layout—Flow Direction; Level of Detail; Level of Precision; Parallel Equipment; Logical Flow vs. Geographic Arrangement; Support Processes; Computer Tools vs. Brown Paper; Qualified Guidance and Coaching; Summary; ; Our Focusing Problem—A Synthetic Fiber Process ; Process Overview; Raw Materials; Step 1: Polymerization; Step 2: Fiber Spinning; Step 3: Draw–Anneal; Step 4: Cut—Bale; Finished Product Storage and Shipping; Order Processing and Production Scheduling; The Synthetic Fiber Manufacturing VSM; ; Developing the Material Flow ; ; Calculating Data Box Parameters; Process Step Data Boxes; Overall Equipment Effectiveness (OEE); Calculating Availability; Calculating Performance; Calculating Quality; Calculating OEE; Remaining Factors; Another Example of OEE; Supplier Data Boxes; Customer Data Boxes; Inventory Data Boxes; Transportation Data Boxes; Summary; ; Material Flow Rates and Takt ; Calculating Takt; Bales; Rope Takt in Gaylords; Annealed Product Takt; Filament Takt; Flake, Spinning, and Polymer Takt; Raw Material Takt; Summary; ; Completing the Data Boxes: Utilization, Delivery Frequency, and Days of Supply; Utilization; Transportation Frequency; Inventory Days of Supply; Summary; ; Mapping the Information Flow; Why Map Information Flow?; Fiber Manufacturing Information Flow; Capacity Constraint Resources; Additional Information Mapping Tools; Summary; ; Developing the Timeline; Timeline Principles; Fiber VSM Timeline; Cash Flow Cycle Time; Summary; ; Finding the Waste—Analyzing the Map; General Impressions from the Current State; Inventory Opportunities; Baler Reliability; Spinning Yield; Long Campaign Cycles (EPEIs); Hot Roll Draw–Anneal; Uncoordinated Scheduling; Capturing Potential Opportunities; ; Scoping the Opportunities; Inventory Opportunities; 1. Raw Material Inventory in Rail Cars Is Too High; 2. Flake Inventory Is High; 3. Filament Inventory Is High; 4. Rope Finished Product Inventory in Gaylords Is Too High; 5. Right Size the Cutter Box Inventory; 6. Bale Finished Product Inventory Is Too High; Equipment Opportunities; 7. Spinning Changeover Losses Are High; Spinning Utilization Is High; 8. Baler Reliability Is Poor; 9. Changeover Improvement—Balers; 10. Reduce the Baler Campaign Cycle (EPEI); 11. Mothball One Baler; 12. Hot Roll Draw–Anneal Reliability and Yield Wastes; 13. Mothball One Polymer Reactor; System-Wide Opportunities; 14. Implement Virtual Cellular Flow; 15. Filament Tub FIFOs after Implementation of Virtual Cells; 16. Implement Pull Replenishment across the Value Stream; 17. Drop the 60 Very Low Demand SKUs; Summary; ; Implementation Strategy and Sequence; Strategy for Implementation of Improvements; Riverside Fiber Plant Future States; Future State Generation 1; Future State Generation 2; Future State Generation 3; Summary; ; Future State Value Stream Maps; Why a Future State VSM?; Future State 1 Map; Future State 2 Map; Future State 3 Map; Summary; ; Supply Chain Mapping ; Why a Supply Chain Map Is Important; Supply Chain Wastes; Effects of Wastes at the Supply Chain Level; Supply Chain Map Components; Future State Supply Chain Map; Supply Chain Map Example; Summary; ; VSM as a Way of Engaging Employees ; Origin of the Problem; A New Paradigm on the Role of Labor; The Nature of Engagement; Summary; ; A Roadmap for Continuous Improvement ; Summary; ; Benefits of Developing a VSM ; Operations That Have Benefitted from Using a VSM; Processing of Large Rolls in a Sheet Goods Plant; Bottling Salad Dressing; Cooling Towers in Polyethylene Production; Producing Waxes for Coating Cardboard Boxes; Improving a Capital Project Execution System; Summary; ; Appendix A: Process Industry Characteristics; Characteristics That Distinguish the Process Industries; Equipment Is Large and Difficult to Relocate; Processes Are Difficult to Stop and Restart; Capital Intensive vs. Labor Intensive; Hidden WIP; Product Differentiation Points; Summary; ; Appendix B: SMED Principles ; SMED Origins; SMED Concepts; Product Changeovers in the Process Industries; Summary; ; Appendix C: Cellular Flow ; Typical Process Plant Equipment Configurations; Cellular Manufacturing Applied to Process Lines; Summary; ; Appendix D: Pull Replenishment Systems ; Why Is Pull Important?; What Is Pull?; Pull in Assembly; Difficulties in Process Plants; Push–Pull Interface; ConWIP; Visual Signals; When to Start Pulling: The Sequence of Implementation; Value Stream Focus; Showing Pull on a Value Stream Map; Summary; ; Appendix E: Cycle Stock and Safety Stock ; Cycle Stock and Safety Stock; Calculating Cycle Stock; Fixed Interval Replenishment Model; Fixed Quantity Replenishment Model; Safety Stock; &am
• Edition: 1st
• Publisher Details: New York : Productivity Press
• Publication Date: 2015
• Extent: 1 online resource, illustrations (black and white)
• Subjects: 658.5; Manufacturing processes; Production management; Value analysis (Cost control); Process control
• Languages: English
• ISBNs: 9781482247695
• Related ISBNs: 9781482247688
• Notes: Note: Includes bibliographical references and index.; Note: Description based on CIP data; item not viewed.
• Access Rights: Legal Deposit; Only available on premises controlled by the deposit library and to one user at any one time; The Legal Deposit Libraries (Non-Print Works) Regulations (UK).
• Access Usage: Restricted: Printing from this resource is governed by The Legal Deposit Libraries (Non-Print Works) Regulations (UK) and UK copyright law currently in force.