“Value Stream Mapping� by
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Learning Framework 1. Introduction 2. The Current State Map 3. Lean Value Stream 4. The Future State Map 5. Achieving the Future State 6. Conclusion 2
Value Stream Mapping Purpose : 1. Introduce Value Stream Mapping in a hands on manner. 2. Develop your ability to “see
the
flow�
and
design future state value streams. 3
VALUE-STREAM IMPROVEMENT and PROCESS IMPROVEMENT VALUE STREAM PROCESS
Stamping Raw Material
The Three Value Streams:
PROCESS
Welding
PROCESS
Assembly Cell Finished Product
Raw Material to Finished Product Concept to Launch Order to Cash 4
Value Stream Mapping Follow a “products” production path from beginning to end, and draw a visual representation of every process in the material & information flow. Then, draw (using icons) a “future state” map of how value should flow.
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Using the Value Stream Mapping Tool Product “Family�
current state drawing
Understanding how the shop floor currently operates. The foundation for the future state.
future state drawing
Designing a lean flow.
plan and implementation
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Focus on One Product Family Determine Product Families via : Similar downstream “assembly” steps and equipment Process Steps & Equipment Spot Weld
Robot Weld
Flash Remove
Paint
Manual Assm.
Fixtures Assm.
Electronic Test
PRODUCTS
LH Steering Bracket RH Steering Bracket Instrument Panel Brace Seat Rail Bumper Brackets
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Levels of a Value Stream
Process level Mapping level to start
Single plant (door to door)
Multiple plants
Across companies 9
Learning Framework 1. Introduction & Getting Started 2. The Current State Map 3. Lean Value Stream 4. The Future State Map 5. Achieving the Future State 6. Conclusion 10
Time Push
Current-State Map showing the Customer
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Team Tips Current State Mapping 1. Mapping the current state : • Review the basic processing steps and calculate the takt time in your team’s breakout room. • Everyone draw while on the shop floor. Be sure to draw both the material & information flows. • Always introduce yourself to operators and tell them what you are doing : “Drawing the total factory flow as part of a training session.’ Show them your drawings. • Select a scribe and combine your drawings into one current state map (in team area). • Calculate total lead time versus processing time. • Make an overhead transparency of the map and select presenters. 12
Team Tips Current State Mapping 2.
Presenting your •
All team members go up front with presenter. State the product family and takt.
•
Present from your overhead transparency. (Less than 5 minutes.)
•
Start with the customer and information flow into the facility.
•
State the lead time vs. processing time.
•
What are the problems you see? Where did you find push and overproduction ?
•
Share any future state thoughts you have so far. 13
Value Stream Loops
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Load-leveling box Kanban are responded to from left to right at pitch increment One row per product type
One column per pitch here pitch = 10 min
Kanban 15
An Example of “Paced Withdrawal”
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