Value Stream Mapping Exercise with Solution: Pump Assembly

This exercise takes you from the current state of a pump assembly line to the future state. The tasks are attached as comments directly to the elements of the map; the model solution is a second template that you can compare using the current/future comparison.

Starting point

Centrifugal pump P20, 300 pieces per day, one shift with 450 minutes of working time. Five processes: machining (75 s, changeover 40 min, batch size 150), subassembly (60 s), final assembly (110 s, 90% uptime, 2% scrap rate), testing (50 s), shipping. Inventory of 150 to 1,500 pieces between them, and a weekly schedule sent to every process.

The six tasks

• Calculate the takt time and compare it with the metric in the tool.
• Explain why final assembly is the bottleneck (effective cycle time vs. takt time).
• Determine the inventory days of the raw housings.
• Calculate the changeover time per piece (changeover time ÷ batch size) for machining, and estimate how a shorter changeover affects effective cycle time, batch size and inventory.
• Set an appropriate finished goods inventory for daily shipments.
• Enter three improvements as kaizen bursts with an owner and a due date.

How to proceed

Open the template "Exercise: current state pump assembly". Click an element to read its task in the comments panel on the right. The metrics bar at the bottom and the checks panel help you verify your work. You can record your answers as comments on the element.

Then load the template "Exercise: solution (future state)" and compare both with the current/future comparison. The solution explains each change in a comment: flow cell, supermarkets, changeover cut to a quarter, FIFO to testing, daily schedule at the pacemaker.

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