value stream mapping
- 1. Value Stream Mapping 1
- 2. Value Stream Mapping • A tool originally used by the Toyota Production System experts to study processes • Developed and refined by John Shook and Mike Rother • Used in manufacturing, engineering and administrative offices by lean experts to improve business processes
- 3. Value Stream Mapping Definition – Special type of flow chart that uses symbols known as "the language of Lean" to depict and improve the flow of inventory and information. 3
- 4. What is a Value Stream? A value stream involves all the steps, both value added and non value added, required to complete a product or service from beginning to end
- 5. 5 Value Stream Improvement & Process Improvement Value Stream Improvement PROCESS PROCESS PROCESS Outgoing Finished Product Incoming Raw Materials Customer
- 6. 6 PURPOSE : Understand the role value stream mapping plays in continuous improvement Draw a current-state map Draw a future-state map Develop an implementation plan Getting Started
- 7. Using the Value Stream Mapping Tool Understanding how things currently operate. This is the foundation for the future state. Scoping the Value Stream Designing a lean flow through the enterprise. Current state drawing Future state drawing Determine the Value Stream to be improved Planning and The goal of mapping! Implementation
- 8. Advantage of Value Stream Mapping & Analysis • Develop a common understanding of the current process – The relationship of process steps – A true picture of the process • Create a baseline to measure improvements against • Define a vision of the future process • Establish common leadership objectives • Identify opportunities for improvement • Design an implementation plan for improvements “If you can’t describe what you are doing as a process, you don’t know what you’re doing.” W. Edwards Deming 8
- 9. Analyzing the Value Stream Planning tool to optimize results of eliminating waste current state VSM future state VSM + + Lean = Basics 9
- 10. A SIMPLE EXAMPLE………….. Info: Location of stapler Info: Where to place staple Pick Up Paper Walk to Stapler Staple Paper Time: 1 sec. Distance: 0 Walk to Desk Put Down Paper Time: 5 sec. Distance: 20 ft. Time: 5 sec. Distance: 20 ft. Time: 2 sec. Distance: 0 Time: 1 sec. Distance: 0 Total Time: 14 sec. Total Dist: 40 ft. Value Added Time: 4 sec. Value Added Dist: 0 Value Added Time: 28% Excess Travel 10
- 11. 11 The Current State Map
- 12. Sample VSM Map 12
- 13. VSM Symbols 13 Value Stream Mapping Symbols
- 14. 14 Current State Drawing Current State Product Family Current State Drawing Future State Drawing Plan and Implementation Determining how production currently operates. Material and Information flows Draw using VSM icons Start with the “door to door” flow Walk the production lines and get actuals No standard times Draw by hand, with pencil Foundation for the Future Site
- 15. 15 TAKT Time TAKT Time Match assembly pace to pace of orders. Rate for assembling based on orders rate. Work Time per Shift TAKT Time = Customer Requirement per Shift 27,600 sec 460 pieces = 60 seconds
- 16. 16 Future State Value Stream
- 17. 17 Future State Drawing Future State Product Family Current State Drawing Future State Drawing Plan and Implementation Designing a LEAN Flow The power behind Value Stream Mapping is you always need a future state! Keep Updating. Use pencil! Material and Information flows Basis for your Work Plan – like a “blueprint” Begin by drawing on Current State 1st iteration assumes existing steps & equipment Can move equipment, combine, take out conveyors, make minor purchases etc. But, there is a Problem!
- 18. 18 Future State Map Future State
- 19. 19