distribution center vsm example_juarez

Customers

ORD

Order input in BPCS

Production

Production of orders

Whs 65

Put material in Whs 65

loc.

C / T = ~5 min

4:10 AM

Up Time = n/a

Opr = none

Working Time = 1 shift

C / T = ~ 120 min

1 cart = 168 units

No smoking test

Opr = 2 operator

Working Time = 1 shifts

BPCS

Creates scheduling &

skid tagsI

Staging10 min

sx

Final Audit

Revise & release product I

Staging20 min

sx

Whs 75

Put material in location Whs. 75

Staging

I

Staging

Whs 75

Run pickable report & release available orders

Whs 65

Input DRP processI

Staging

I

Staging

Whs 65

Pull material from location

Whs 65

Put material in metro carts I

Staging

Whs 65

Process by packer station

Whs 65Process by

shipper station/Confirm

I

Staging

Whs 65

Put material in skidI

Staging

Whs 65

Stretch wrap & put in truckI

Staging

Ship & billRelease the

truck & process billing

I

Staging

EDI

EDI

Transfer of orders

EDI

BPCS

ORDERSEDI

BPCS

Varsity

Priority codes 99,50,49

EDIImpromtu

C / T = 180 min

Up Time = n/a

Opr = 1 cell



C / T = ~ 20 min

1 cart = 168 units

waste = transportation

Opr = 1 operator


1302.5 min

413 min25 min10 min 30 min 15 min 7.5 min 15 min ~ 180 min 25 minC / T = ~20 min

5:00 AM

Up Time = n/a

Opr = none



I

C / T = ~ 60 min

Release is combine

Opr = 1 operator


C / T = ~ 30 min

All batch combine

Waste - transportation

Opr = 1 operator


C / T = ~ 35 min

I batch

Waste – extra transaction

Opr = 1 operator


C / T = ~ 15 min

1 pickable report

Opr = operator


C / T = ~ 10 min

1 batch


Opr = 1 operator


C / T = ~ 5 min

1 batch


Opr = 1 operator


C / T = ~ 3 min

1 order

Opr = 1 operator


C / T = ~ 3 min

1 order

Opr = 1 operator


C / T = ~ 7 min

1 order

Opr = 1 operator


C / T = ~ 15 min

1 full skid

OTTR 96 % in 24 hrs

Opr = operator


C / T = ~ 60 min

1 truck

Opr = 2 operator


Whs 65Run pickable

report & release order

IRA 94%

3 orders batch

Waste -waiting

Waiting time = 90 min

VSM ACTUAL

Whs 65

Pick TYCO batch pulling

C / T = ~ 30 min

All batch combine


Opr = 1 operator


Whs 75

Pick UPS/ FEDEX

C / T = ~ 30 min

All batch combine (10 orders)


Opr = 1 operator


I

Staging10 min

Whs 75

Process order UPS #1/

FEDEX #1

C / T = 2.5 min

Order =

Waste - Waiting

Opr = 1 operator


Whs 75

Process order UPS #2/

FEDEX #2

C / T = 2.5 min

Waste - Waiting

Opr = 1 operator


Whs 75

Put material on FEDEX or UPS’s skid

Order = 1

Whs 75

Wrap / Strap/ Load on

TruckI

Staging 5 min

I

360 min

Staging

d

Whs 75

C / T = 10 min


Opr = 1 operator


Order = 1

C / T = 1 min

Waste - Waiting

Opr = 1 operator


Order = 1

Do Customs paperwork

C / T = 30 min

Waste - Waiting

Opr = 1 operator


Order = 1 & 2 shift orders

d

Whs 75

Customs process

C / T = 60 min


Opr = 1 operator



d

Whs 75

Security release.Driver

documentation

C / T = 30 min


Opr = 1 operator



d

METRICOS

Safety = 0 Accidents / Incidents

Quality = 0 Shipping Issues / Internal discrepancies

Cost = Overtime 27 hrs per week (1&2 shifts)

20 min 180 min

120 min

5 min

20 min10 min 20 min 90 min 60 min

30 min 10 min 2.5 min 5 min 2.5 min 1 min 360 min 10 min 30 min 60 min 30 min

= Total NVA

= Total VA

846 min

230 min

EDI

Vastera

Vastera

EDI

Optima

Optima

Audit

Internal audit`

Whs 75

C / T = ~ 20 min

Opr = 1 operator


Waste overprocessed

Pull material from location for

LTLs orders

Put material in pallets I

Staging

Whs 75

Process by picker station

Process by shipper station/ConfirmI

Staging

IStaging

Whs 75

Stretch wrap & put in truck I

Staging

Ship & billRelease the

truck & process billing

I

Staging

607.5 min

314 min

25 min 7.5 min 15 min ~ 180 min 25 minC / T = ~ 5 min

1 batch


Opr = 1 operator


1 order

Opr = 1 operator


1 order

Opr = 1 operator


C / T = ~ 15 min

1 full skid

OTTR 96 % in 24 hrs

Opr = operator


C / T = ~ 60 min

1 truck

Opr = 2 operator


15 min 60 min12 min

3 orders batch

Waste -waiting

Whs 75 Whs 75

= Total VA

= Total NVA

C / T = ~ 12 min C / T = ~ 12 min

All batch for LTLs

March 2008

VSM Actual 1

Distribution Center for Juarez Life Safety

May 2009

EDI

Receive Order

SAP

Order input in SAP

Production

Production of orders

Whs 65

Put material in Whs 65

loc.

C / T = ~10 min

4:00 AM

Up Time = N/A

Opr = none


C / T = ~5 min

4:10 AM

Up Time = n/a

Opr = none


SAP

Creates scheduling &

skid tags

I

Staging

10 min

sx

Final Audit

Revise & release product

Staging

f

I I

Staging

Whs 65


Whs 65

Put material in metro

carts

I

Staging

Whs 65

Process Packer & shipper station

Whs 65

Put material in skid

Whs 65

Stretch wrap & put in truckI

Staging

Ship & bill

Release the truck &

process billingI

Staging

EDI

EDI

Transfer of orders

EDI

SAP

ORDERSEDI

BPCS

VarsityPriority codes 99,50,49

EDIImpromtu

C / T = 180 min

Up Time = n/a

Opr = 1 cell

Working Time = 1 shiftPriority codes 99,50,49

= Total NVA

= Total VA

0.05 days

0.08 days

0.1 days

342 min

233 min

25 min15 min ~ 180

min25 min

C / T = ~20 min

5:00 AM

Up Time = n/a

Opr = none

Working Time = 1 shiftPriority codes 99,50,49

C / T = ~ 15 min

1 pickable report

Opr = operator


C / T = ~ 10 min

1 batchWaste - transportation

Opr = 1 operator


C / T = ~ 5 min

1 batch

Waste - transportationOpr = 1 operator


C / T = ~ 3 min

1 order

Opr = 1 operator


C / T = ~ 7 min

1 order

Opr = 1 operator


C / T = ~ 15 min

1 full skid

OTTR 96 % in 24 hrs

Opr = operator

C / T = ~ 60 min

1 truck

Opr = 2 operator


Whs 65

Run pickable report &

release order

VSM FUTURE

C / T = ~ 30 min

All batch combine


Opr = 1 operator

Whs 75

Pick UPS/ FEDEX

C / T = ~ 30 min



I

Staging

10 min

Whs 75

C / T = 2.5 min

Order =

Waste - Waiting

Opr = 1 operator


Whs 75


Whs 75


Truck

I

360 min

Staging

d

Whs 75

C / T = 10 min



Order = 1

C / T = 1 min

Waste - Waiting

Opr = 1 operator


Order = 1


C / T = 60 min

Waste - Waiting

Opr = 1 operatorWorking Time = 1 shift


d

Whs 75

Customs process

C / T = 30 min


Opr = 1 operator



d

Whs 75


documentation

C / T = 30 min


Opr = 1 operator



20 min

180 min

120 min

10 min

5 min

20 min10 min 30 min

30 min 10 min 2.5 min 1 min360 min

10 min 60 min 30 min 30 min

= Total NVA

= Total VA

701 min

227.5 min

EDI

Vastera

Vastera

EDI

Optima

Optima

Audit

Internal audit`

Whs 75

C / T = ~ 20 min

Opr = 1 operator


Waste overprocessed

20 min

C / T = ~ 10 min

1 batch

Waste - transportationOpr = 1 operatorWorking Time = 1 shifts

10 min

IRA 94%


for LTLs orders


Staging

Whs 75

Process by picker station

Process by shipper station/

ConfirmI

Staging

I

Staging

Whs 75


Staging

Ship & bill

Release the truck &

process billingI

Staging

25 min 7.5 min 15 min ~ 180 min

25 minC / T = ~ 5 min

1 batch


Opr = 1 operator


1 order

Opr = 1 operator


1 order

Opr = 1 operator


C / T = ~ 15 min

1 full skid

OTTR 96 % in 24 hrs

Opr = operatorWorking Time = 1 shifts

C / T = ~ 60 min

1 truck

Opr = 2 operator


15 min 60 min

15 min 25 min180 min5 min

12 min 12 min

25 min 7.5 min

3 orders batch

Waste -waiting

Whs 75 Whs 75

= Total VA

= Total NVA

C / T = ~ 12 min C / T = ~ 12 min

All batch for LTLs

Opr = 1 operator

20 minC / T = ~ 120 min

1 cart = 168 units

No smoking test

Opr = 2 operator


15 min 10 min 5 min 25 min 3 min 15 min7 min 15 min 25 min60 min

Process Packer & shipper station

VSM Actual 2Distribution Center for Juarez Life Safety

Customers

sx

Wh 3000 / 3005

Put material in location Wh 3000 & 3005

Staging

Wh 3000 / 3005

Run pickable report & release

available orders

EDI

SAP

ORDERS

C / T = ~ 20 min

1 cart = 168 units


Opr = 1 operator


I

C / T = ~ 15 min

Release is combine

Opr = 1 operator


Waiting time = 90 min

VSM ACTUAL

Wh 3000 / 3005

Pick UPS/ FEDEX

C / T = ~ 30 min



I

Staging

10 min

Wh 3000 / 3005

Process order UPS /

FEDEX

C / T = 5 min

Order =

Waste - Waiting

Opr = 1 operator


Wh 3000 / 3005


Wh 3000 / 3005


Truck

I

360 min

Staging

d

Wh 3000 / 3005

C / T = 10 min



Order = 1

C / T = 1 min

Waste - Waiting

Opr = 1 operator


Order = 1


C / T = 60 min

Waste - Waiting

Opr = 1 operatorWorking Time = 1 shift


d

Wh 3000 / 3005

Customs process

C / T = 30 min


Opr = 1 operator



d

Wh 3000 / 3005


documentation

C / T = 30 min


Opr = 1 operator



20 min 90 min 15 min

30 min 10 min 5 min 1 min360 min


= Total NVA

= Total VA

586 min

75 min

EDI

Vastera

VasteraEDI

Optima

Optima

Audit

Internal audit`

Wh 3000 / 3005

C / T = ~ 20 min

Opr = 1 operator


Waste overprocessed

20 min

C / T = ~ 10 min

1 batch


Opr = 1 operatorWorking Time = 1 shifts

10 min

IRA 94%


for LTLs orders


Staging

Wh 3000 / 3005

Process by picker station I

Staging

I

Staging

Wh 3000 / 3005


Staging

Ship & bill

Release the truck &

process billingI

Staging

412.5 min

77 min

25 min 7.5 min 15 min ~ 180 min

25 minC / T = ~ 5 min

1 batch


Opr = 1 operator


1 order

Opr = 1 operator


1 order

Opr = 1 operator


C / T = ~ 15 min

1 full skid

OTTR 96 % in 24 hrs

Opr = operatorWorking Time = 1 shifts

C / T = ~ 60 min

1 truck

Opr = 1 operator


15 min 30 min

15 min 25 min180 min5 min

20 min 12 min

25 min 7.5 min

3 orders batch

Waste -waiting

Wh 3000 / 3005

= Total VA

= Total NVA

C / T = ~ 20 min C / T = ~ 12 min

All batch for LTLs

Print orders Automatically

Implement bar Code system

Opr = 1 operator

60 min

Wh 3000 / 3005


Truck

Jan 2010

VSM Actual 3

Distribution Center for Juarez Life Safety

Customers

EDI

Receive Order

ORD

Production see order

C / T = ~10 min

6:00 AM

Up Time = N/A

Opr = none


C / T = n/a

Up Time = n/a

Opr = none


Produce by customer order

and qty

sxAutomatic creates shipping

paperworkI

Staging

Shipping

Pack material

EDI

EDI

Transfer of orders

EDI

BPCS

ORDERS


C / T = 5 min

Up Time = n/a

Opr = 1



C / T = 5 min

Opr = 1 operator


= Total NVA245 min

265 min

240 minC / T = 180 min

6:10 AM

Up Time = n/a

Opr = 1 cell



C / T = 5 min

Opr = 1 operator


C / T = 20 min

Opr = 1 operator


C / T = 10 min

Opr = 1 operator


C / T = 10 min

Opr = 1 operator


20 min180 min10 min 0 min

5 min 240 min

6:10 AM

Production Production

Receive scan direct to C.O

ShippingTransport material to shipping

5 min

Shipping

5 min

Shipping

Put material on skid

9:10 AM

9:15 AM

9:20 AM 9:40 AM

C / T = 15 min

Opr = 1 operator


9:55 AM

Machine = Forklift

15 min

Shipping

Put material on truck

2:00 PM

Machine = Forklift

Shipping Shipping

Ship Material Billing


C / T = 10 min

Opr = 1 operator


2:00 PM

Machine = Forklift

VSM IDEAL

July 2010Distribution Center for Juarez Life Safety

distribution center vsm example_juarez

Documents