Agile & Lean Manufacturing

IM-515

Group Members
S. M. Hasan Waqar IM-54/2015-16
Adnan Naseem IM-39/2015-16
INTRODUCTION OF THE COMPANY
Krystalite Plastic Industry Pvt Ltd
Group of Industry of Gatronova.
Founded in 2007 in order to utilize the waste of Garton and
Novatex Industry.
Main Departments Include
i.Sheet Line
ii.Thermoforming
iii.Blow Molding
Main Customers are
i.Kolson
ii.Bisconi
iii.KFC
iv.Burger King
v.Nestle
vi.Hilal
vii.Rooh afza etc
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

VSM originated from TPS(Toyota Production System)

Its a Mapping Tool.
Uses symbols known as The language of Lean.
This tool is used primarily to identify, demonstrate and
decrease waste, as well as create flow in the
manufacturing Process.
Extremely Powerful tool that combine Material
processing steps with Information Flow as well as other
important related data.
With this powerful lean tool an organization can Plan,
implement and improve its lean journey.
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

Value Stream Maping has 4 Steps.

i.Define and Pick the Product Family.
ii.Create The Current State VSM
iii.Create the Future State VSM.
iv.Develop an Action Plan to make the FSVSM.
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

Define and Pick the Product Family

i.VSM can be created for single product or a Family of
Products.
ii.A Family is a group of products with similar Routine,
similar process times and customers with similar needs
and demands.
iii.Similar means that there can be some varition but all
members have a core set of operations that are same.
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

Define and Pick the Product Family
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

Create The Current State VSM
i.Basic Information of Process and Information system.

SHEET LINE:
3 Sheet Line Machines.
Total Working time available is 720Mins.
Lunch, Tea breaks and Cleaning time are of 60min ,10(2)min and 15min
respectively.
i.Available time is 625Min.
2 working shifts per day and 6days a week.
Total possible output of the machine is 14400Kg/Day and 7200Kg/Shift.
Cycle Time of the Process is 6Sec/Kg.

DESIGNER(Thermoforming):
i.1 Thermoforming Machine.
Total Working time available is 720Mins.
Lunch, Tea breaks and Cleaning time are of 60min ,10(2)min and 15min
respectively.
Available time is 625Min.
i.2 working shifts per day and 6days a week.
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

Create The Current State VSM
i.Basic Information of Process and Information system.

PRINTING MACHINE:
1 Printing Machine.
Total Working time available is 720Mins.
Lunch, Tea breaks and Cleaning time are of 60min ,10(2)min and 15min
respectively.
i.Available time is 625Min.
2 working shifts per day and 6days a week.
Total possible output of the machine is 69120Pcs/Day and 34560Pcs/Shift.
Cycle Time of the Process is 1.25Sec/Pc.

PACKING MACHINE:
i.1 Thermoforming Machine.
Total Working time available is 720Mins.
Lunch, Tea breaks and Cleaning time are of 60min ,10(2)min and 15min
respectively.
Available time is 625Min.
i.2 working shifts per day and 6days a week.
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

Create The Current State VSM
i.Basic Information of Process and Information system.

SUPPLIER:
Raw Material is provided by Gatron and Clariant.
Main items are Resin, Ereema and Masterbatch.
5days inventory

CUSTOMER:
Total Customer Requirement is 400000Pcs/Month and 15000Pcs/Daily.
1000Pcs are packed in a cartoon for dispatch.
Shipments are made daily and as per the customer requirement.

COMMUNICATION:
i.Production Planning provides Daily Plan to all individual departments.
ii.Customer emails the tentive requirement through Email.
Production Planning emails the Raw Material requirement through email.
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

Create The Current State VSM
i.Some Common VSM icons that are used during making of CSVSM

Customer Supplier

I Inventory
Transportation
Kaize
n Kaizen Burst
Manual
Electronic Information
Information
Process Box Material flow
 Gatron Customers
Industries SHEET LINE:
3 Ton Material inventory as per the management
decision.
Part weight is 9.8gm.
Ereema Total daily demand 15000pcs.
Calculation:
Resin =(9.8/1000)*15000=147Kg 400000pcs/mon
Since product are made from sheet so there are 60% th
Master Skeleton formed and 40% finished goods.
15000Pcs/daily
=147/.4=367.5Kg/day
Batch Lead Time =Inventory/Customer Cartons=1000p
Demand
Weekly Lead Time=3000/367.5=8.16Days
cs
Daily

SHEET LINE

I 3
5Day
s
I
CT= 6 Sec
3ton
C/O=480Min

UP/T=90%

6Sec
8.16Days
5Day
 Gatron Customers
Industries DESIGNER(Thermoforming):
250000Pcs inventory as per the
management decision.
Part weight is 9.8gm.
Ereema Resin Total daily demand 15000pcs.
Calculation: 400000pcs/mon
Master Batch Lead Time th
=Inventory/Customer Demand 15000Pcs/daily
Lead Time Cartons=1000p
=(250000/15000)=16.7Day cs
Weekly
Daily

SHEET DESIGNER
LINE

I 3 4
5Day
s
I I
CT= 6 CT=0.25 25000
3to Sec
Sec
C/O=480Min C/O= 360Min
0 Pcs
n
UP/T=90% UP/T= 90%

6Sec 0.25Sec
8.16Days 16.7Da
5Day ys
 Gatron Customers
Industries PRINTING MACHINE:
250000Pcs inventory as per the
management decision.
Part weight is 9.8gm.
Ereema Total daily demand 15000pcs.
Resin Calculation: 400000pcs/mon
Lead Time th
Master =Inventory/Customer Demand 15000Pcs/daily
Batch Lead Time Cartons=1000p
=(250000/15000)=16.7Day cs
Weekly
Daily

SHEET DESIGNER PRINTING M/C

LINE

I 3 4 3
5Day
s
I I I
CT= 6 CT=0.25 25000 CT=1.25 25000
3to Sec Sec
Sec
C/O=480Min C/O= 360Min
0 Pcs
C/O= 300Min
0 Pcs
n
UP/T=90% UP/T= 90% UP/T=95%

6Sec 0.25Sec 1.25Sec

8.16Days 16.7Da 16.7Da
5Day ys ys
 Gatron Customers
Industries PACKING MACHINE:
250000Pcs inventory as per the
management decision.
Part weight is 9.8gm.
Ereema Total daily demand 15000pcs.
Resin Calculation: 400000pcs/mon
Lead Time th
Master =Inventory/Customer Demand 15000Pcs/daily
Batch Lead Time Cartons=1000p
=(250000/15000)=16.7Day cs
Weekly
Daily

SHEET DESIGNER PRINTING M/C PACKING

LINE

I 3 4 3 2
5Da
ys I I
I I
CT= 6 CT=0.25 25000
CT=1.25 25000
CT= 0.1 25000
3to Sec Sec Sec 0 Pcs
Sec
C/O=480Min C/O= 360Min
0 Pcs
C/O= 300Min
0 Pcs
C/O= 10
n
Min
UP/T=90% UP/T= 90% UP/T=95% UP/T= 99%

6Sec 0.25Sec 1.25Sec 0.1Sec

8.16Days 16.7Da 16.7Da 16.7Da
5Day ys ys
 Krystalite Plastic Industry Pvt Ltd

Value Stream Maping:

iii. Future State VSM
By Merging Sheet line and Designer it is possible to avoid Tranportation
and invenoty buildup time which will ultimately reduce the lead time.
By merging Printing and Packing again we can save the transportation and
inventory buildup time.
Reducing the Inventory after thermoforming to the daily demand level we
can reduce the lead time.