1. TAKT Time (s) 57.6
Demand 500
Frequency Daily
C/T (s) 3600
C/O (s) 0
Uptime (%) 100
Yield (%) 110
Shifts 1
Quantity 275 Chickens
Time (s) 7200 Quantity 270 Quantity 270 Quantity 260 Quantity 250
Time 1800 Time 600 Time 600 Time 600
Frequancy Daily * 1
C/T (s) 3600 C/T (s) 1200 C/T (s) 1800 C/T (s) 3000 C/T (s) 1200 Time (s) 3600
C/O (s) 0 C/O (s) 180 C/O (s) 0 C/O (s) 60 C/O (s) 0
Frequency Daily Uptime (%) 100 Uptime (%) 90 Uptime (%) 100 Uptime (%) 80 Uptime (%) 100
Yield (%) 108 Yield (%) 108 Yield (%) 104 Yield (%) 100 Yield (%) 100
Shifts 1 Shifts 1 Shifts 1 Shifts 1 Shifts 1
LEAD
7200 1800 600 600 600 TIM E (s) 10800
VALUE
3600 3600 1200 1800 3000 1200 3600 TIM E (s) 18000
TAKT Time (s) 57.6
Demand 500
Frequency Daily
C/T (s) 3600
C/O (s) 0
Uptime (%) 100
Yield (%) 110
Shifts 1
Quantity 275 Chickens
Time (s) 900 Quantity 270 Quantity 270 Quantity 260 Quantity 250
Time 600 Time 600 Time 600 Time 60
Frequancy Daily * 1
C/T (s) 3600 C/T (s) 1200 C/T (s) 1800 C/T (s) 3000 C/T (s) 1200 Time (s) 3600
C/O (s) 0 C/O (s) 180 C/O (s) 0 C/O (s) 60 C/O (s) 0
Frequency Daily Uptime (%) 100 Uptime (%) 90 Uptime (%) 100 Uptime (%) 80 Uptime (%) 100
Yield (%) 108 Yield (%) 108 Yield (%) 104 Yield (%) 100 Yield (%) 100
Shifts 1 Shifts 1 Shifts 1 Shifts 1 Shifts 1
LEAD
900 600 600 600 60 TIM E (s) 2760
VALUE
3600 3600 1200 1800 3000 1200 3600 TIM E (s) 18000
TAKT Time (s) 57.6
Demand 500
Frequency Daily
C/T (s) 1200
C/O (s) 0
Uptime (%) 100
Yield (%) 110
Shifts 1
Frequency Daily
Frequancy Daily * 1
Time (s) 3600
C/T (s) 3600 C/T (s) 1800 C/T (s) 3600
C/O (s) 0 C/O (s) 180 C/O (s) 60
Uptime (%) 100 Uptime (%) 90 Uptime (%) 80
Yield (%) 108 Yield (%) 108 Yield (%) 100
Shifts 1 Shifts 1 Shifts 1
LEAD
1200 0 0 0 TIM E (s) 1200
VALUE
0 3600 1800 3600 TIM E (s) 9000
(working time)
(that’s 275 chickens per
The customer intends to have the product delivered to them by
the manufacturer on time so it can be ready for sale.
CUSTOMER DELIVERY DETAILS
Delivery
PACKAGEING & LABELING
Chicken Fillet Value Stream Map
STORES BUCKET HOLDING QUARTERS
KILL & PLUCK HANGED & SKINNED
Package & Labeling
Delivering
SUPPLIER/M anor Farm
INSPECTION
Fillets placed in plastic
packaging with companys logo,
price, bord bia logo and bar
code. Up to 24 packages placed
in machine packer.
Live Chicken Stock
Packaging
(1hr gathering products)
PLANNING
Live stock Chickens
Packaging
Chickens Stunned by electric
floor, Killed instantly. Feathers
are plucked andinsides are
cleaned out
Chicken brests fall off line,
pinned on studs thats fixed to a
converiour belt. Personel at far
end of converior cut brests into
fillets
VALUE ADDED TIME
NON-VALUE ADDED
TIME
Lables
Lables Kill & Pluck
Hanging
TRANSPORTING TO PACKINGLINE IN M OTION
Supervalue/Costomer wants Daily order of 500
Chicken Fillets from 250 chickens. That on
average 1 every 57.6 seconds
Pinning & Cutting
PURCHASING
PINNING & CUTTING
PURCHASING
DEFINITIONS
POTENTIAL
IMPROVEMENTS
PLANNING
Good Needed
Inspection
NON-VALUE ADDED
TIME
VALUE ADDED TIME
Chicken Fillet Value Stream Map
PLANNING
Inspection of goods, run tests
and eliminate poor products
GOODS IN
SLAUGHTER HOUSE DELIVERY HANGING LINE IN M OTION
GOODS IN
Skin is removed, possible
brusing of chicken can be seen
now/removed from process
where they are hung. Line travels
through factory to the fillet line.
CUSTOMER DELIVERY DETAILS
Inspection of goods, run tests
and eliminate poor products
Chickens Stunned by electric
floor, Killed instantly. Feathers
are plucked andinsides are
cleaned out
Skin is removed, possible
brusing of chicken can be seen
now/removed from process
where they are hung. Line travels
through factory to the fillet line.
Chicken brests fall off line,
pinned on studs thats fixed to a
converiour belt. Personel at far
end of converior cut brests into
fillets
Fillets placed in plastic
packaging with companys logo,
price, bord bia logo and bar
code. Up to 24 packages placed
in machine packer.
The customer intends to have the product delivered to them by
the manufacturer on time so it can be ready for sale.Delivery
INSPECTION KILL & PLUCK SKINNED PINNING & CUTTING PACKAGEING & LABELING
TRANSPORTING TO PACKING
(1hr gathering products)
(working time)
(that’s 275 chickens per
Packaging Package & Labeling
Lables Delivering
Inspection
SUPPLIER/M anor Farm
PLANNING Lables Kill & Pluck
Hanging
Live stock Chickens Pinning & Cutting
Chicken Fillet Value Stream Map
PLANNING
PURCHASING Supervalue/Costomer wants Daily order of 500
Chicken Fillets from 250 chickens. That on
average 1 every 57.6 seconds
Live Chicken Stock Good Needed
Packaging
Live Chicken Stock Good Needed
Packaging Inspection & Killing
SUPPLIER & DELIVER/M anor
Farm
PLANNING Lables Skinning & Plucking
Cutting & Packing
Live stock Chickens Delivering
Packaging
Lables
INSPECTION & KILLING BAY SKINNING & PLUCKING
(that’s 275 chickens per
The customer intends to have the product
delivered to them by the manufacturer on time
so it can be ready for sale.
Supervalue/Costomer wants Daily order of 500
Chicken Fillets from 250 chickens. That on average
1 every 57.6 seconds
PAT opperates the pinning and
cutting process and directs the
output to packaging using the
same portocal of PAT.
CUTTING & PACKAGING
Delivery
CUSTOMER DELIVERY DETAILS
Inspection of chickens using
PAT, then killing using electric
floor.
Chickens are Hung on conveyer
belt which is feed through a
machine that plucks and skins
the chicken.
UPTIME: Time somethingis workingand was available to work
YIELD: Amountproduced of a product.
C/T: Cycle time, how longittakes.
C/O: Change overtime.
TAKT TIME: Average unitproduced on time needed to meetthe customers demand.
VALUE ADDED TIME: Time the customeris willingto pay for servive done.
NON_VALUEADDED TIME: Time the customeris not willingto pay for work done.
SHIFTS: Shifts perworkingday.
As itis, the actual time the customeris willingto pay forthe services (VALUEADDEDTIME) is lonly a third more than actual time spentthe customeris not willingto pay (NONE-VALUEADDEDTIME), so there is a lotthat could be done to
eliminatethis waste time thatand make the service more efficient.
These wastage time include:
1. Good in @ 7200s = 2 hrs
2. Storage of good @ 1800 s = 30 mins
3. Bucket holdingstores @600s = 10mins
4. Line in motion @ 600s = 10mins
5. Transportation to packing@ 600s = 10mins
In orderto make the process more efficientwe meetto try and eliminatewhatis notneeded and minimise whatcurrently exists.
1. GOODS IN: As it stands ittakes 2 hours to delivergoods to the factory for processing. Itwould be very hard to eliminatethis time as itis an essential partof the process, therefore we must find a way to reduce the time taken to
deliverethe productthatboth safe for the driverand supply factory and efficient in terms of cost the company. Suggestions would be to look fora cheaperand closersupplierof material and look aboutproducinglivestock nearerthe
factory or the factory producingtheirown live stock. This could eliminate the time to deliverby at leasthalf and making the process more efficient. New timeforGOODIN would be setat 15 mins = 900s
2. STORAGE OF GOODS: As itstands, afterinspection the company stores the chicken in aconfined areafor30 mins before they are sentto the slaughterhouse. This process could be completely eliminated leavingjustthe time needed to
transportthe livestock to the slaughterhouse. New timeand partof process, SLAUGHTER HOUSE DELIVERY at 10 mins = 600s
3. BUCKET HOLDING AREA: As itstand, afterthe chickens are killed and plucked they are held in buckets foraperiod of 10mins before beinghanged and skinned. This could be improved by simply eliminatingthis step in the process and
by simply addingin aprocess whereby the chickens are hanged straightaway onto a movingline and then sentto the area where there skin will be removed. This will resultin makingthe time more efficientin skinningthe chickens and
increase the speed of the overall process. New partto process is hangingat 10mins = 600s.
4. LINE IN MOTION: Unfortunately there is littlethatcan be done to change this process as any change in speedingup the line could resultin excessive wearof mechanicalparts, have asafety effecton personal workingaround the line
and could resultin the productfallingoff the line due to excessivespeeds. On the plus side, itis estimated thatchanges in the areas previously identified would resultin the overall process beingspeed up and with that the time at which
the line was in motion would be reduced savingenergy and costin maintenance costs. Currentprocess of 10mins = 600s would still apply butwith the line operatingata shorteroperatingtime.
5. TRANSPORTATION TO PACKAGING: As itstands the producthas to transportwithin the factory to the packagingarea before packagingand labellingcan take place. This could be minimized greatly if the packagingand labellingareawas
closerto the pinningand cuttingarea. New proposal to have closerquarters of contact between cuttingand packagingareas resultingin less travellingtimes between quarters. New Transportation to packagingis 1min = 60s.
VALUE ADDED/NONE VALUEADDED VALUE ADDED/NONE VALUEADDED
OLD RESULTS VS NEW RESULTS
18000/10800 18000/2760
VALUE ADDED MODIFICATIONS
Despite the factthat the customeris willingto pay forVALUE ADDED parts of the process, itis essential thatimprovements are made to modify the process to reduce costand time in the process:
Currently VALUEADDED part of the process consistof:
1. Supply chain
2. Inspection
3. Killingand plucking
4. Hanging and skinning
5. Pinningand cutting
6. Packagingand labelling
While some of these are essential to the process and the time within these can’tbe changed, some otherparts can be modified alongwith changes to NONEVALUEADDED parts to give a more efficientprocess.
These changes include:
1. The supply chain and the new delivery process would mean thatthe raw material would be sourced within the confines of the factory and therefore would consistof asingle partof the process in itself. Total time of this part of the
process wouldbe 1200s or 20mins.
2. The Inspection could be implemented into the killingand pluckingprocess partwhereby the chickens are taken into the killingbay and using PAT(Process Analyticall Technology)the chickens could be tested and monitored and then
slaughtered there within the confines one room, thus eliminatingthe stock holdingbay and furtherspeedingup the process. Results couldcut the inspectiontime by half, total time of the process wouldbe 3600s or 1hr.
3. Hanging and Skinningwould solely consistof hangingthe chickens on the conveyerline afterkillingand inspection where they are taken to the skinningareawhere they mightbe plucked and skinned togetherin asingle process saving
time. Process renamedSkinningand Plucking.New time set to 1800s or 30mins.
4. Line in motion to pinningand cuttingprocess mightnotchange much but the pinningand cuttingprocess could be modified whereby the human intervention is replaced with aPATinjective consistingof machine involvementin this part
of the process and leadingstraightinto packagingand labelling, thus eliminatingthe wholehuman involvementin the process exceptformaintenance. UsingPATmightimprove the time expectancyfor this part of the process the new
name for this process part might be calledCutting and Packaging and resultin a time of 3600s or 1hr.
1
1
2
3 4
2
3 4