Value Stream — Automotive Door Line
Body-in-white front door line from steel coil to trim, showing the classic ~1% flow efficiency of a batch-and-queue plant and marking the paint shop as the monument that breaks takt.
Make it your own.
title "Front door line — current state"
supplier "Steel coil (Tier 1)"
customer "Final assembly" demand: 960/day
available 900m/day # two 7.5 h shifts
control "MES weekly schedule"
process "Blank + stamp" { ct: 32s; co: 22m; uptime: 88%; operators: 2; shifts: 2; batch: 600; fpy: 99% }
inventory 1800 blanks
process "Inner panel weld" { ct: 48s; co: 12m; uptime: 82%; operators: 3; shifts: 2; fpy: 97% }
inventory 420 panels
process Hemming { ct: 41s; co: 8m; uptime: 91%; operators: 1; shifts: 2; fpy: 98% }
wait 3h
process "E-coat + paint" { ct: 26m; co: 45m; uptime: 76%; operators: 4; shifts: 2; fpy: 92% }
inventory 260 doors
process "Trim + glass" { ct: 96s; co: 0; uptime: 94%; operators: 5; shifts: 2; fpy: 96% }
info "Weekly build order" from customer to control electronic
info "Daily ship schedule" from control to "Trim + glass" electronic
info "Coil release" from control to supplier manual