Value Stream Mapping

Introductions & Objectives

Value Stream Mapping

Introductions and Objectives |

Introductions » » »

Who are you?

How long with YESCO?

Something that few in the group know about you?

Value Stream Mapping

Introductions and Objectives |

Objectives »

What do you want to get out of this?

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My expectations?

– You will be able to observe a process and develop a current state map from it – You will be able to see waste and have ideas on how to eliminate or minimize it.

Value Stream Mapping

Course Outline

Value Stream Mapping

Course Outline |

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What are Value Streams & Value Stream Maps?

Identifying Value Streams Mapping The Current State Creating & mapping The Future State Value Stream Mapping

What are Value Stream Maps?

Value Stream Mapping

What Are Value Streams | Definition

A Value Stream….

is the set of all actions (both value added and non value added) required to bring a specific product or service from raw material through to the customer.

» » » » »

Not individual processes Not just parts This is the big picture Encompasses door to door –

raw materials to finished product, plus flow of information

Can eventually reach to other plants, suppliers, customers Value Stream Mapping

What Are Value Stream Maps | Definition

A Value Stream Map…

is a visual representation of the value stream, including processes and information flow

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A pencil and paper tool that helps you to see and understand the flow of material and information as the product makes it’s way through the value stream.

The best way to teach ourselves to SEE value, and SEE wastes Helps build a vision of a Value Added Flow Value Stream Mapping

What Are Value Stream Maps | Types “Whenever there is a product (or service) for a customer, there is a value stream. The challenge lies in seeing it.”

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3 typical enterprise value streams: – – – Manufacturing – Converting Raw Materials to Finished Product Engineering - Concept to Launch (R&D) Administrative - Order to Cash Value Stream Mapping

Identifying Value Streams

Value Stream Mapping

How to Map the Value Stream | Choosing a Product Family » A product family is a group of products that pass through similar processing steps and over common » Must map product family value streams, too complicated otherwise Value Stream Mapping

How to Map the Value Stream | What to Map » » » » Not mapping the organization Map the FLOW of products through the organization.

Consider information flow Map what is currently happening in the flow, not “the way it’s supposed to be” » The only way to get this is to go to where the work is being done and observe personally » While mapping you will have great ideas on what might change for the better, don’t loose those (become Kaizen Bursts) Idea Value Stream Mapping

Map Current State

Value Stream Mapping

How to Map the Value Stream | Tools » Use pencil, paper, Post-it Notes » Why not to start with a computer???

» Drawing by hand is...

» Quicker, fewer delays » Can be done by anyone, not just the techies » » Focus will be on the flow, not on how to use the computer Manually drawing fine tunes you mapping ability » » ERASER Going to the Gemba to collect data » Always collect the current state while walking it YOURSELF » Stopwatch Value Stream Mapping

How to Map the Value Stream | What Type of Map??

» Several TYPES of maps to use......

» Traditional VSMs Value Stream Mapping

How to Map the Value Stream | Tools » Traditional Mapping Icons Value Stream Mapping

How to Map the Value Stream | What Type of Map??

» Several TYPES of maps to use......

» Swim Lane VSMs Value Stream Mapping

How to Map the Value Stream | Drawing the Current State map » » » » Pick Value Stream to map Decide what kind of map to use (traditional or swim lane) Walk the value stream » First pass to gain rough understanding » Second time to gather more detail Collect pertinent data, such as...

» Cycle Time – the time between pieces coming off the process » Lead Time – the time it takes for a piece to go through the process » » » » » » » » » Uptime Available Time Shifts of Operation Overall required Takt Time (Demand of the customer ÷ Available Time) Number of stations / number of operators per process Batch Qty Yeild % How many pieces in process How many pieces waiting between processes Value Stream Mapping

How to Map the Value Stream | Drawing the Current State map » » With data collected, draw the map Capture improvement ideas along the way with the Kaizen Burst Idea » Calculate the total Production Lead Time (the time it takes to go from the start to finish, entire value stream) » » Calculate the total processing time (the sum of all the cycle times) Draw map on large paper, everyone agrees “this is the what we saw at the Gemba ” Value Stream Mapping

Map Future State

Value Stream Mapping

How to Map the Value Stream | Drawing the Future State map How will the Future State be different from the Current State?

» Consider the ideas that came up during the 1 st mapping process Ideas » Also consider these guidelines......

1.

Eliminate/Reduce Non-Value Adding Steps 2.

3.

4.

5.

6.

7.

8.

Produce to the takt time Develop continuous flow whenever possible Use “supermarkets” to control productions where continuous flow is no possible Try to schedule at only one production process (pacemaker process) Distribute part variety evenly over time at the pacemaker process Create a “pull” by releasing small increments of work at the pacemaker process Develop ability to “make every part every day” More Ideas Value Stream Mapping

How to Map the Value Stream | Drawing the Future State map » » Draw the Future State including the all the changes the team feels are realistic “right now” Make assignments to “make it happen” » » Go-Dos Kaizen events » Team projects

Without this, Mapping is Waste

Value Stream Mapping

Let’s try our hand at it!

Value Stream Mapping

Quick Reference Sheet

A Value Stream is the set of all actions (both value added and non value added) required to bring a specific product or service from raw material through to the customer.

A Value Stream Map is a visual representation of the value stream, including processes and information flow. It’s purpose is to help us SEE the waste in our process

Map one Value Stream (Product Family) at a time Swim Lane VSM Kaizen Bursts help you capture improvement ideas while mapping

Ideas

Tools to use include: Pencil, paper, eraser, stopwatch, Going to the Gemba, teams, your ideas Traditional VSM Guidelines for improvements

1.

2.

3.

4.

Reduce/Eliminate Non-Value Adding Steps Produce to the takt time More Ideas Develop continuous flow whenever possible Use “supermarkets” to control production where continuous flow is not possible 5.

6.

7.

8.

Try to schedule in only one production process (pacemaker process) Distribute part variety evenly over time at the pacemaker process Create a “pull” by releasing small increments of work at the pacemaker process Develop ability to “make every part every day” Make it happen – without this step the whole thing is a waste Value Stream Mapping