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7/31/2019 Value Stream Mapping S2012
1/19
Dr. Richard E. White
Value Stream
Mapping
7/31/2019 Value Stream Mapping S2012
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Overview
VSM Key Tool in Continuous Improvement
Understanding What the Customer Values
Muda
Current State
Future State
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VSM
VSM Key Tool in Continuous Improvement
Graphical Representation of Value Stream
Flow of Materials and Information Through
Transformation to Deliver Product/Service
to Customer
VSM has an Enterprise Focus rather than a
Functional Focus
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Five Principles of Lean
1.) Value
2.) The Value Stream3.) Flow
4.) Pull
5.) Perfection
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Muda
Waste
Type-1 muda
non-value added but deemed necessary
Type-2 muda
non-value added and unnecessary
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VSM Current State
Identify VSM Team
Leader
Assembled Team
Data Collection
Identify Major Process Steps
Quantify the Process
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VSM Current State (cont.)
Decide Value added and Non-Value Added
Activities
Estimate Times
Sum the Individual Times
Review Process
Quantify Overall Lead Times
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VSM Current State (cont.)
Determine the Information Flow
Validate the VSM
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VSM Information Typically
Collected for Current State
1. The end customers requirements
2. Customers schedules3. Cycle time or processing time
4. Changeover time
5. Reliability of equipment
6. Quality yield information
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VSM Information Typically
Collected for Current State
(cont.)
7. Quantities (batch sizes)8. Number of operators & shifts
9. Hard copies of information
10. Inventory levels
11. Queue or waiting time
12. Information flow
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VSM Icons
Dedicated process
Shared process
Customer/supplier
Data box
Work cell
http://www.strategosnic.com/value-stream-mapping-3.htm
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VSM Icons
Inventory
Shipments
Material push
Supermarket
Material pull
http://www.strategosnic.com/value-stream-mapping-3.htm
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VSM Icons
Safety stock
External shipment
Manual information
Electronic information
Production Kanban
http://www.strategosnic.com/value-stream-mapping-3.htm
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VSM Icons
Withdrawal Kanban
Kaizen Burst
Operator
Timeline
Information
http://www.strategosnic.com/value-stream-mapping-3.htm
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VSM Future State
Analyze Your Current State VSM
Start With Your Customers View
Identify Issues in the Value Stream that
Affect the Customer
Quantify Customer Demand Rate (takt
Time)
Identify Where Flow is Less than Ideal
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VSM Future State (cont.)
Blockages Can be Traced to Muda
Remove Blockages
Look for Muda, Mura, and Muri
Consider two future views
Future State
Incremental Improvement State
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VSM Future State (cont.)
Update the Current State VSM to Reflect
the New Current State
Compare the New Current State to theFuture State
Start Mapping Again
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Aylesbury Pressings: Current State(Steering Bracket)
Press Paint Final Ass
C/O = 15 min
C/T = 0.2 secC/O = 30 min
C/T = 2 sec
C/O = 5 min
C/T = 3.5 min
C/O = nil
C/T = 90 min
(v/a) = 3 min
C/O = nil
C/T = 1 min
Dispatch
SupplierCustomer
Production
ControlMRPII
200 1780 nil
623
Six Monthly and Monthly Forecasts
Weekly Schedulescoils
Daily Schedules
Weekly Requirement
Daily call off
Monthly forecasts
Weekly orders
500
some
kanban
230
35
16nil
13
2074
324
0.2 sec
2500min 1000m
2 sec180s
1620m
218s
3115m0m
60 s10370m
total l/time=18695 min
V add time = 650 sec
Assemble
imbalance
sequenceTransport
inventory
changeover
inventory
InventoryOEE
issues
Level?
Frequency?
Takt=2x420/170=5 min
Shared resources shaded
VA time vs
Cycle time
90m
Rework/
quality
Responsive?
Which most
reliable?
Blanking(Progression line)
Press
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Allied Products Partner: Current State(Wine Box - Top Plate)
Cross-Cut Sub Assy Final Assy
C/O = 15 min
C/T = 10 sec
57,600 sec. avail
C/O = 15 min
C/T = 12 sec.
57,600 sec. avail
C/O = 30 min
C/T = 7 sec.
57,600 sec. avail
C/O = nil
C/T = 36.0 sec.
57,600. avail
C/O = nil
C/T = 18 sec.
57,600 sec. avail.
Staging
SupplierCustomer
Production
ControlMRPII
42 42 42
4000
Six Monthly and Monthly Forecasts
Weekly Schedules
wood Daily Schedules
Weekly Requirement
Daily call off
Monthly forecasts
Weekly orders
truckload
42
10 sec
16 hrs 7 min.
12 sec 36 sec
4 min. 54 sec.
7 sec
96 min.25 min. 12 sec.
18 sec
8 min. 24 sec.
total time= 18 hrs. 22 min.
V add time = 1 min. 18 sec.
Takt=57,600 sec./3,200=18 sec.
Shared resources shaded
Rip Saw Brand
Dispatch
2 days
nails nailsfoil