KitschLtdisamanufacturerofdesignerkitchenworktopproducts,establishedin1984.ObjectiveTheobjectiveoftheexerciseistomapthecurrentstateanddesignthefuturestateforthekettlevaluestream,usingMaterialandInformationFlowAnalysis.KitschmanufacturesarangeofkettlesfortheUK,GermanandFrenchmarkets,whichvaryincolourandelectricalspecifications.Thefollowinginformationsummarisesusefulinformationgleanedfrom1days’worthofpre-arrangedinterviewswithKitschpersonnelandafactorytour.ProductionManagementKitschLtdhasinjectionmoulding,press,electricalassembly,paint,assemblyanddispatchdepartments.Thekettleskeletoncomprises4plasticcomponents,asillustratedattheendofthebrief.Thebodyisbought-infromFungusMouldsLtdandthehandle,lidandelectricalboxaremouldedin-house.Thehandleandlidaretransportedtotheassemblyarea.Theelectricalboxgoestotheelectricalassemblydepartmentwherebought-incomponentsareassembledandtested,thenontotheassemblydepartmentwiththeappropriateleadandplug.Allothercomponentsusedtoassembleeachkettlearebought-inexceptfortwopressedmetalcomponents,whichoriginateinthepressdepartment.Oneoftheseisaninsertforthelidwhichafterpressingistakentothepaintdepartmentandthentotheassemblyline.Theotherpressedcomponentisthebaseplate,whichlinesthebottomofthekettle.ThisistakenstraighttotheassemblylineafterthepressdepartmentKitschnormallyoperates5daysaweek.Alldepartmentsrunadoubledayshiftexceptthemouldingdepartment,whichoperateswithatrebleshift.Everyshiftiseighthourslong,withtwopaid10-minuteteabreaksandapaid30-minutesmealbreak.Themanagementalsoallows10minutesonceperdaytocleanequipmentand5minutesatthestartofeveryshiftforateammeeting.Theproductionmanagerexplainedthatthismeeting‘wastoempowerhispeoplenowthattheyaredoingkaizen’.Alldepartmentsstopproductionforalltheseperiods,sincenoequipmentisfullyautomatic.ThenewplantmanageratKitschiskeentoavoidoverproductionintheplantandwantstoconnecttheproductionprocesstothecustomerasvisuallyaspossible.SalesDepartmentKitschworkswithadistributorcalledLaitwhichprocessesordersfromretailersandcollectsproductsfromKitschondailymilkroundstotheretailers’distributioncentres.Laitadvances30-,60-and90-dayforecaststoKitsch,whichbenefitsfromafairlyconstanttotalweeklydemandperproductvariant.ThisenablesLaittoprovideKitscheveryThursdayafternoonwithaConfirmedOrderListforthefollowingweek.AtypicalConfirmedOrderListisincludedasFigure1.EquipmentforchickitchensKettlesaremanufacturedinWhite,Green,YelloworMauveplastic.Foreachofthesecoloursthereisonlyonecolourfortheinsertinthekettlelid.Thefinishedproductwillalsohaveanelectricalkitthatisspecificforitsdestinationcountry.KettlesofeverycolouraremadefortheFrenchandGermanmarkets,butnomauve,greenoryellowkettlesareevermadefortheUK.ProductionControlDepartmentTheproductioncontroldepartmentloadsthe30-,60-and90-dayforecastsfromLaitontoanMRPsystem.Thesystemgeneratesaweeklybuildscheduleforeachdepartment,whicharedistributedeveryMonday.EveryThursdaytheproductioncontroldepartmentreceivesalistofconfirmedordersfromLaitforthefollowingweek.Thefollowingdaytheproductioncontroldepartmentsendsacopyofthelisttothedispatchdepartment.TheproductioncontroldepartmentadmittedthattheWIPfiguresontheMRPsystemwere‘notnecessarilyaccurate’.Quickcountsofkettle-relatedinventoryinalldepartmentsatthetimeofthefactorytouraredetailedinFigure2.PurchasingDepartmentTheMRPsystemisusedtogeneratefirmordersforall...
