Michele Levasseur © 2015

I find money in the value streamby

Eliminating Waste

Michele Levasseur © 20152

Michele Levasseur © 2015 3

• This is why I can deliver solutions • Through the path I have traveled in my career.• Turn to the next slide to see where I have

traveled along the way

Michele Levasseur © 2015

Michele Levasseur © 2015

How we did it……..• Started with specific goal.The goal of this project will be to increase the number of on time shipments, maximize output of labor force, increase the ability to adapt to varying levels of demand, level output based forecast with predicted yield loss, increase throughput to match customers requirement

Supply Chain voice of client and voice of the customer

• Reviewed customers orders to find out why jumps in market only at certain times of year

• Our company could not match peaked demands

• Addressed issues with our client found out that it was their internal promotions causing distribution points to lower volume to almost nothing resulting in loss in service to end customer.

Michele Levasseur © 2015

Michele Levasseur © 2015

Supply Chain result from investigation

• Our client chose to level volumes at distribution points based on history of year 2012

• Leveling assured the right amount of product at the distribution points

• The customer was never out of parts.• Our client had happy customer’s and we were

able to respond to client demand.

Michele Levasseur © 2015

Process Time-m 0.75 Process Time-m 0.63 Process Time-m 0.21 Process Time-m 0.75 Process Time-m 0.32 Process Time-m 0.61 Process Time-m 1.71%Downtime 0.0% %Downtime 0.0% %Downtime 0.0% %Downtime 0.0% %Downtime 0.0% %Downtime 0.0% %Downtime 12.0%Setup Time-m 0 Setup Time-m 0 Setup Time-m 0 Setup Time-m 0 Setup Time-m 0 Setup Time-m 0 Setup Time-m 0#Setups/Shift 0 #Setups/Shift 0 #Setups/Shift 0 #Setups/Shift 0 #Setups/Shift 0 #Setups/Shift 0 #Setups/Shift 0# Shifts 1 # Shifts 1 # Shifts 2 # Shifts 2 # Shifts 2 # Shifts 2 # Shifts 2% Yield 100.00% % Yield 100.00% % Yield 100.00% % Yield 100.00% % Yield 100.00% % Yield 100.00% % Yield 97.00%Batch size 40 Batch size 40 Batch size 40 Batch size 40 Batch size 40 Batch size 40 Batch size 40

In warehouse People Reqd 1 People Reqd 1 People Reqd 1 People Reqd 1 People Reqd 1 People Reqd 1 People Reqd 11920 People Trained 6 People Trained 6 People Trained 6 People Trained 5 People Trained 2 People Trained 2 People Trained 5

Represents a change

PercentInventoryDays InvEffective Proc Time-mWork time/shift-mTotal Work timeEffective YieldTakt-mAdj Takt for Yield, Uptime, Setups-mProc Time % Adj TaktCurrent ResourcesResources req'd/dayTime req'd/day-m

No constraint

Potential constaint

MoldSand Paint Humidifier Preheat Mixing

100% 100% 100% 100% 100%

De-gassing

100% 100%0 40 40

0.00 0.127.20 0.00 0.12 0.12 0.00402420

0.6 0.2 0.8 0.3 0.6 1.70.8460.0 460.0460.0 460.0 460.0 460.0 460.0

460.0 920.0 920.0 920.0100% 97%920.0

100% 100% 100% 100% 100%920.0460.0

1.15 2.30 2.30 2.30

2.30 1.96

2.30

1.15 1.15 2.30 2.30 2.30

2.301.15

54.78% 9.32% 32.61% 13.91%1 1

26.67%1 1 1 1

87.01%65.22%

0.55 0.09 0.33 0.14245.33 800.53

0.27300.00 252.00 85.71 300.00 128.00

0.870.65

Flow from Sand to Paint

Improve ventilation at Sanding to allow

Painting at machneON MONDAY

start one operator 1/2 hr earliet to load

preheater

Investigate oven cure time and if needed

Sand and paint on

same machine

Root cause of molding

defects

Value Stream Map gives a monetary value to each step in the process