Value Stream Mapping. Introductions & Objectives Value Stream Mapping

ValueStream

Mapping

Introductions& Objectives

Value Stream Mapping

Introductions

» Who are you?» How long with YESCO?» Something that few in the group

know about you?

Introductions and Objectives |


Objectives

» What do you want to get out of this?

» 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.

Introductions and Objectives |


Course Outline


» What are Value Streams & Value Stream Maps?» Identifying Value Streams» Mapping The Current State» Creating & mapping The Future State

Course Outline|


What are Value Stream Maps?


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

What Are Value Streams| Definition


A Value Stream Map…is a visual representation of the value stream, including processes and information flow

» 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


What Are Value Stream Maps| Definition

“Whenever there is a product (or service) for a customer, there is a value stream. The challenge lies in seeing it.”

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


What Are Value Stream Maps| Types

IdentifyingValue Streams


» 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


How to Map the Value Stream | Choosing a Product Family

» 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)


How to Map the Value Stream | What to Map

Idea

Map Current State


» Use pencil, paper, Post-it Notes» Why not to start with a computer???


How to Map the Value Stream | Tools

» 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

» Several TYPES of maps to use......» Traditional VSMs


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

» Traditional Mapping Icons


How to Map the Value Stream | Tools

» Several TYPES of maps to use......» Swim Lane VSMs


How to Map the Value Stream | What Type of 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


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

» 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”


How to Map the Value Stream | Drawing the Current State map

Idea

Map Future State


» Consider the ideas that came up during the 1st mapping process

» Also consider these guidelines......1. Eliminate/Reduce Non-Value Adding Steps2. Produce to the takt time 3. Develop continuous flow whenever possible4. Use “supermarkets” to control productions where continuous flow is no

possible5. Try to schedule at only one production process (pacemaker process)6. Distribute part variety evenly over time at the pacemaker process7. Create a “pull” by releasing small increments of work at the pacemaker

process8. Develop ability to “make every part every day”


How to Map the Value Stream | Drawing the Future State map

Ideas

How will the Future State be different from the Current State?

More Ideas

» 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


How to Map the Value Stream | Drawing the Future State map

Let’s try our hand at it!


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

Kaizen Bursts help you capture improvement ideas while mapping

Tools to use include:Pencil, paper, eraser, stopwatch, Going to the

Gemba, teams, your ideas

Traditional VSM


Quick Reference Sheet

Swim Lane VSM

Guidelines for improvements1. Reduce/Eliminate Non-Value Adding Steps2. Produce to the takt time 3. Develop continuous flow whenever possible4. Use “supermarkets” to control production where continuous

flow is not possible5. Try to schedule in only one production process (pacemaker

process)6. Distribute part variety evenly over time at the pacemaker

process7. Create a “pull” by releasing small increments of work at the

pacemaker process8. Develop ability to “make every part every day”

Make it happen – without this step the whole thing is a waste

Ideas

More Ideas

Documents

Value Stream Mapping. Introductions & Objectives Value Stream Mapping