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CHAPTER 6 CURRENT STATE VALUE STREAM MAPS FOR PLANT C AND D This chapter presents the value stream maps developed from Plant C and D using data collected at each facility. For each facility, only one production line was chosen to develop a value stream map. The selection of the production line was based on the product with the greatest demand. Cycle times, changeover times, batch sizes, number of employees, availability of machines, inventory levels, and shipment data was collected by using the methodology of Shook and Rother (2003) as discussed in section 3.3.1. Then, the different processes were graphically shown in a current state value stream map (VSM) using Visio 2013. The VSMs created in this section will serve as key for the future state maps of the respective manufactures in study. 6.1 PLANT C Plant C main flooring products consist of 2.25” and 3.25” red and white oak pre-finished and un-finished flooring. They have two flooring production lines; however, only one production line was selected: 3.25” prefinished flooring. The production line consists of 7 processes which are: grading and stacking, air drying, kiln drying, surface planner, rip saw, moulder, and pre- finishing. Customer orders for pre-finished floor are received primarily via email (pdf) to designated incoming order email address. Lumber orders are placed either by email (pdf) or fax. In both cases, flooring and lumber, there can be phone and/or email conversation regarding availability and lead times prior to order submission. Customer demand for 3.25” pre-finished flooring is 325.5 MBF on average per month. Plant C has from 85 to 105 customers that vary with seasonality of demand. The company works 20 days per month. Shifts are 8.5 hours per day, with 30 minutes for lunch and 2 breaks of 10 minutes each. An optimized program called LISA is used to control and 94PDF Image | Impact of Vacuum-Drying on Efficiency of Hardwood Products
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