Another method for collecting data is direct data intake from production shop floor and internal company documentation, and pulled up data from company’s
database SAP. Researcher will also perform interview and brainstorming with production team, supply chain team, maintenance team, logistic team and purchasing
team
4.4 Data Processing and Analyzing Method
Data that has collected will be processed to solve the problem using Value Stream Mapping tool follow below steps:
1. Selecting Product Family
The first step starts with selecting a product family. One point to understand clearly before starting the mapping is the need to focus on one product family.
Identify product families from the customer end of the value stream. A family is a group of products that pass through similar processing steps and over common
equipment in downstream processes. Data needed for this step is mainly production output of products that
produced from 6 to 12 months period and all of the processes steps of each product go through. The tool to use for this is a PQPR Product Quantity Product Routing
matrix. This tool will help to identify which product or in some cases products to focus in on by creating Pareto Chart to see what products they made the most and
pass through same process and machine.
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2. Define Current-State Map
Once the value stream selected, the researcher observed and collected data related to the flow of information and material from raw material to finished goods.
Beginning with the information flow, the researcher used the support from planner to collect information concerning the communication with customers and suppliers, the
production controls orders and forecast from customers, the production controls orders and forecast to suppliers, the frequency of orders released to the production
supervisor, and the frequency of orders released to each operation within the value stream.
In order to map the current state, researcher walked thru the floor door to door to collect data, this began with the receiving area and worked toward the shipping
area. The researcher collected information about material flow, inventory between processes, and process attributes including:
1. Quantity of product required per month in work centre selected 2. Quantity of products shipped per day and per month
3. Number of shipping days per month 4. Supplier delivery schedule
5. Regular planned down time 6. Available production time minus breaks
7. Number of operators per process 8. Number of shifts per process
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Also, the researcher collected the following individual metrics at each process involved:
1. CT cycle time Cycle Time CT in this observation refer to definition on ‘Learning to See’
book created by Mike Rother and John Shook which is how often a part or product actually is completed by a process, as timed by observation. Also, the
time it takes an operator to go through all of their work elements before repeating them. The instrument used to gather it was a stopwatch to collect
actual information, not standard time that company have.
2. CO changeover time The changeover time was determined by manually timing how long it takes
the operator to setup the work centre in order to make a different pack size. 3. Available uptime on-demand machine uptime
The available uptime within a process is the percentage of time in which a machine or process is available on demand. This can be calculated by
subtracting the changeover time from the total availability and then dividing by the total availability time.
Once data has collected and ordered the researcher calculated daily requirements and takt time, and began to map the current state of the value stream
selected. The first step was to become familiar with the value streams symbols and then start drawing the map following the steps mentioned in Chapter II. Main tools
Devi Adhriany Rahayu :Building Model Of Basic Stability For Productivity Improvement Journey In PT.Dow Agrosciences Indonesia By Utilizing Value Stream Mapping VSM In Production Shop Floor, 2009
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that will be used for this step are stopwatch, pencil and direct observation sheet or blank sheet.
There are few mapping tips given in “Learning to See” book created by Mike Rother and John Shook as follow:
1. Always collect current-state information while walking along the actual pathways of material and information flows yourself.
2. Begin with a quick walk along the entire door-to-door value stream, to get
