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Title: Introduction to Value Stream Mapping
Description: This note comprises the notes comprises the basics of Value Stream Mapping. Ideal for theoritical knowledge gain on value stream mapping in the manufacturing industries Guidelines are from Lean Enterprise Institute ( LEI )
Description: This note comprises the notes comprises the basics of Value Stream Mapping. Ideal for theoritical knowledge gain on value stream mapping in the manufacturing industries Guidelines are from Lean Enterprise Institute ( LEI )
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OVERHEAD 1
Training to See
A Value Stream Mapping Workshop
Purpose:
1
...
2
...
© LEI
OVERHEAD 2
Value Stream Improvement
& Process Improvement
VALUE STREAM
PROCESS
PROCESS
PROCESS
CUSTOMER
STAMPING
Raw
Material
WELDING
ASSEMBLY
CELL
Finished
Product
© LEI
OVERHEAD 3
Value Stream Mapping
A) Follow a product’s production path from beginning to end,
and draw a visual representation of every process in the
material & information flows
...
© LEI
OVERHEAD 4
© LEI
OVERHEAD 5
Using the Value Stream Mapping Tool
product family
current state
drawing
future state
drawing
Understanding how the shop floor
currently operates
...
Designing a lean flow
...
Assm
...
The Value
Stream Manager
Value Stream Managers should make their progress
reports to the top manager on site
...
Material and Information flows
future state
drawing
Draw using icons
Start with the “door to door” flow
plan and
implementation
Have to walk the flow and get actuals
• no standard times
• draw by hand, with pencil
Foundation for the Future State
© LEI
OVERHEAD 10
“ACME Stamping” Data Set
Acme Stamping Company produces several components for vehicle assembly plants
...
These components are sent to the State Street Vehicle Assembly Plant (the customer)
...
The customer orders in multiples of trays
...
The components are then staged & shipped to the vehicle assembly
plant on a daily basis
...
• Steel coils are supplied by Michigan Steel Co
...
ACME PRODUCTION CONTROL DEPARTMENT:
• Receives State Street’s 90/60/30-day forecasts and enters them to MRP
• Issues Acme 6-week forecast to Michigan Steel Co
...
• Receives daily firm order from State Street
• Generates MRP-based weekly departmental requirements based upon customer order,
WIP inventory levels, F/G inventory levels, and anticipated scrap and downtime
• Issues weekly build schedules to Stamping, Welding, and Assembly processes
• Issues daily shipping schedule to Shipping Department
© LEI
OVERHEAD 12
“ACME Stamping” Data Set (continued)
PROCESS INFORMATION:
All processes occur in the following order and each piece goes through all processes
...
© LEI
PRACTICAL EXERCISE 1
Team Tips
Current State Mapping
1
Team Tips
current state mapping
Calculate
total lead
time versus
processing
time
...
Everyone draw while on the shop floor
...
Always introduce yourself to operators and tell them what you are doing: “Drawing
the total factory flow as part of a training session
...
Select a scribe and combine your drawings into one current state map (in team area)
...
Make an overhead transparency of the map and select presenters
...
State the product family and takt
...
(Less than 5 minutes
...
State the lead time vs
...
What are the problems you see? Where did you find push and overproduction?
Share any future state thoughts you have so far
...
Use pencil!
current state
drawing
• Material & Information flows
• Basis for your Work Plan — like a “blueprint”
future state
drawing
• Begin by drawing on Current State
• 1st iteration assumes existing steps & equipment
plan and
implementation
Can move equipment, combine, take out conveyors,
make minor purchases, etc
...
System Efficiency
How fast should we produce?
© LEI
OVERHEAD 18
TAKT Time
Synchronizes pace of assembly to match pace of sales
...
59
sec
...
2) Supplying process produces to replenish what was withdrawn
...
400 A
Tuesday
...
400 C
Friday
...
Better: Every Part Every Day
Monday: 140 A, 100 B, 160 C
Important:
Near-zero changeover
time and frequent
changeovers at the
Pacemaker Process!
Even Better: Every Part Every Ship Window
Monday
50B
70A
80C
50B
70A
80C
© LEI
OVERHEAD 25
What Happens to a Lean Flow…
...
if a defective part is included with good parts?
© LEI
OVERHEAD 26
Paced Withdrawal at the Pacemaker
• What amount of work do you schedule and take away at the pacemaker?
• This amount = your management time frame
...
g
...
Future State Mapping
1
MAPPING THE FUTURE STATE:
Use the list of future state questions
...
Then draw a future state map
...
•
•
•
•
2
PRESENTING YOUR FUTURE STATE MAP:
Present from your transparency
...
Tie it to business objectives
...
Break your future state into “loops”
...
Make a VS Plan: What to do by when
...
Now relate the FS Map to your layout
...
VS Manager completes VS Review form in advance
...
Conduct VS Reviews walking the flow
...
Daily
PRODUCTION
CONTROL
90/60/30 day
Forecasts
Daily
Order
MRP
State Street
Assembly
920 pcs/day
500 ft coils
Takt =
460 minutes = 60 sec
...
2 Shifts
Coils
Daily Ship
Schedule
RLLRLL…
Daily
pitch = 20 min
...
20
STAMPING
3
200 T
4
1
1
...
5 days
Work ent
Cont5 sec
...
5 days
time
2 days
165 sec
...
5 days
1 sec
...
S
...
S
...
S
...
S
Title: Introduction to Value Stream Mapping
Description: This note comprises the notes comprises the basics of Value Stream Mapping. Ideal for theoritical knowledge gain on value stream mapping in the manufacturing industries Guidelines are from Lean Enterprise Institute ( LEI )
Description: This note comprises the notes comprises the basics of Value Stream Mapping. Ideal for theoritical knowledge gain on value stream mapping in the manufacturing industries Guidelines are from Lean Enterprise Institute ( LEI )