VERY URGENT 1 HOUR TO GO VSM PROJECT HW
AHMET 
PBJVSMforstudents1.pptxBUS 370-01
Lean practices in Operations Jeffrey Coffin
Name: __________________________Date __________________
Peanut Butter and Jelly Sandwich Manufacturing Value Stream Map Exercise
The assignment is to create a current condition Value Stream Map given the information provided. Complete the map on this page and hand in on the due date.
Our PB&J manufacturing company goes by the name of C & J's PB&J Inc.; we have a daily demand of 700 pieces with the following arrangement.
• Hours per shift: 8
• Break minutes per shift: 30
• Shifts per day: 1
• Days per week: 5
• Each process step is staffed with 1 (one) operator.
• Count two pieces of bread as one subassembly since they move together down the production line.
We did a process study and learned that; there were 486 sub-assemblies (972 pieces of bread) in between the jelly application and packaging stations. We also identified there were 359 pieces of WIP after the peanut butter application department and 128 finished assemblies ready to go to shipping.
During the '"go see" walk we timed each operation and found that the cycle time for peanut b utter was 25 sec., jelly was 30 sec. and packaging was 42 sec.. We also noticed that each process step seemed to be working in isolation. In other words, the lady working at the peanut butter application seemed to produce as many units as she could and then pushed them along to the jelly application process.
Information flow:
Production schedules each process step in isolation. In other words, each work station gets its unique production schedule manually.
The customer sends 30 days electronic forecasts as well as electronic daily orders. We send our bread supplier an electronic weekly forecast.
1. Start by calculating the Takt time:_
2. Complete the VSM on the back of this sheet and hand it in on the day it’s due.
1
The 5-Why analysis can now begin with the direct cause. In this case, they took it down to 6 Whys.
Introduce reverse logic to test 5 Why. For each answer, you should be able to reverse the order and insert “therefore.” If it doesn’t work, then the cause chain is not correct. In this case:
There is no common library of standard items; therefore, they need to be entered manually.
Standard items need to be entered manually, which is time-consuming; therefore, we have minimal standard items.
We have minimal standard items; therefore, a high quantity of data needs to be entered.
A high quantity of data needs to be entered; therefore, an error was made
And so on…
Class members may note that this example on the ones on previous pages don’t necessarily have perfect reverse logic. This can be a good discussion point – can ask the class where the break is and what might have been a better path.
Grade points available:
Demand and Takt time correctly calculated and located in the box: 1.5 pts.
Process steps identified in order with correct number of operators identified: 5 pts.
Cycle time boxes drawn in and times correct for each process: 2.5 pts.
Information flow identified correctly: 5 pts.
Push arrows between the right processes: 1 pts.
Inventory shown correctly between processes: 2.5 pts.
Layout shown with correct # of operators from data sheet: 2.5 pts
Starbursts with problem opportunities identified: 5 pts.
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Total available points 25 pts.
2 point bonus if it’s done in pencil
