Value Stream Mapping for High Mix Production

Gienow Windows and Doors produces custom windows and doors for new houses, low-rise building and renovations. Each product is different in terms of size, shape, color, glass and options. This situation creates a scheduling problem that requires special attention when trying to balances the loads on different production lines. This presentation will discuss the issues of high mix production and how the value stream mapping tool can be used to identify areas of improvement. The presentation also discusses addition tools including a production simulator and a resource allocation program that further assists with a high mix production system.

Gienow Windows and Doors was founded in 1947. It has been under the current ownership since 1983. The head office is located in Calgary, with regional offices in Edmonton, Kelowna, Prince George and Richmond BC. There are sales representatives in Red Deer, Lethbridge, Saskatchewan, Victoria and Nanaimo. Today the company employs about 800 people with annual sales of over $100M. The main manufacturing facility is located in the Foothills Industrial Park in the SE part of Calgary. Gienow started to develop their just-in-time delivery production system in 1985 has enjoyed many years of growth and profitability. By making to order, Gienow uses a pull system that has reduced finished goods inventory to virtually zero. Their use of automation is extensive and is fully integrated with their manufacturing system the majority of which has been developed in house. Current lean initiatives are focused on the shop floor and issues caused by high mix production are being address with the use of value stream mapping and software simulators.

Paul Dean, VP Information Systems

Paul Dean has a master’s in Computer Science and has spent the last 25 years working in the manufacturing sector, As VP if Information Technology, he has been responsible for the development of an Integrated Manufacturing System at Gienow Windows and Doors. The systems at Gienow rely extensively on integrated automated equipment. The manufacturing process is based on mass customization using one-of-a-kind and one-piece flow production methods. The majority of products are made to order and delivered just-in-time. Prior to working for Gienow, Dean had extensive commercial system experience in the UK, South Africa and Canada.