Product Development Value Stream
Mapping Manual (PDVSM)
Presented By
Hugh McManus
Metis Design
3/27/03
Acknowledgements
•
Joyce
•
Lt. Rich Millard, USAF
•
•
•
•
Tyson Browning
Jim Chase
David Slack
Joshua Bernstein
•
•
LAI Faculty and Staff
LAI PD contributors
web.mit.edu/lean
©Massachusetts Institute of Technology McManus- 032603 2
Practical Guide to PD
Value Stream Mapping
•
A “Rother and Shook” for Product Development
•  More details necessary for the complexities of PD
•  Details and background for lean experts
•  Practical advice for in-the-field use
•
Repository of LAI knowledge
•  Four+ years of PD team experience
•  References and attributions
•  Not an academic product
•
Member Best Practices
•  Suggested “cookbook”
•  Options and resources
•  Running examples and other aids
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©Massachusetts Institute of Technology McManus- 032603 3
Focus: Door to Door PD Process
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PDVSM Manual Outline
•
•
•
•
•
•
1.0 INTRODUCTION: LEAN ENGINEERING PROCESS IMPROVEMENT
2.0 GETTING STARTED
3.0 MAPPING THE CURRENT STATE VALUE STEAM
4.0 IDENTIFYING AND ELIMINATING WASTE
5.0 IMPROVING THE PROCESS
6.0 STRIVING FOR PERFECTION
•
•
•
Running Example
Metrics and other aids
Appendices
•  APPENDIX A: METHODS AND EFFECTIVENESS
•  APPENDIX B: SAMPLE DATA COLLECTION FORM
•  APPENDIX C: SECOND EXAMPLE PDVSM
•  APPENDIX D: PDVSM CHECKLIST
•  NOTES AND REFERENCES
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1.0 Motivation and Effectiveness
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Interpreting Lean for Engineering
Manufacturing
Engineering
Define Value
Visible at each step, defined
goal
Harder to see, emergent goals
Identify Value Stream
Parts and
material
Information & knowledge
Make process flow
Iterations are waste
Iterations often beneficial
Customer pull
Driven by Takt time
Driven by needs of enterprise
Perfection
Process repeatable without
errors
Process enables innovation
and cuts cycle time
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2.0 Establishing Bounds and
Interfaces
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Local Value Emphasis
Activities accumulate information, eliminate risk, use resources
Risk"
Info"
Process
Outcome"
Value
Create this
Value
Value
Realized"
Efficiently
Time
Adapted From Chase, “Value Creation in the Product Development Process”, 2001.
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3.0 Mapping the Current State
•
•
Mapping Information Flows
Process Mapping Symbols
Task
Revie
w
Outcome A
<Outcome C>
Answer B
Decision
Answer A
<Answer C>
Iterative Flow
Major
Flow
“Feeder” Flow
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Mapping Best Practices
•
Follow the Work
•
Collect the Information Yourself
•
Exploit Existing Process Information, Yourself
•
Map “In Pencil”
•
Map the Whole Value Stream
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Example Value Steam:
Aero-Mechanical Prelim. Design
Requirements
and Constraints
1
Choose
Configuration
6
Weight
Analysis
Global Aero.
Environment
Config
Review
2 Create
Moldline
Drawings
3
Aerodyn.
Analysis
4 Create
Mechanical
Drawings
Drawing
Review
Material
Properties
7
Stability
Analysis
5 Define
Structural
Requirements
Reformat
Drawings and
Models
9
Develop
FEM
A
8
Loads
Analysis
Global Loads
Environment
A
10
SSL
Analysis
SSL
Review
to 1, 4, 5, 8, 9,
or 10
web.mit.edu/lean
11 Create
Manufacture
Plan
Manufact.
Review
to 1, 4, or 11
12
Develop
Report
Final
Review
Report and
Presentation
to ANYWHERE
©Massachusetts Institute of Technology McManus- 032603 12
Including Process Data:
Best Practices
•
Concentrate on what you need
•
Exploit what you can find
•
Make do with what you have
•
Be honest
•
Dig deep (only) when you must
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Process Data Metrics
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Example with Metrics and
Timelines
Requirements
and Constraints
1
Choose
Configuration
Global Aero.
Environment
I
WT: 12
CT: 24
IPT: 8
Config
Review
CT: 4
IPT: 2
2 Create
Moldline
Drawings
CT: 40
IPT: 24
4 Create
Mechanical
Drawings
CT: 40
IPT: 24
Information
Gathering
CT: 24
IPT: 4
6
Weight
Analysis
I
CT: 8
IPT: 4
3
Aerodyn.
Analysis
7
Stability
Analysis
CT: 40
IPT: 32
Drawing
Review
CT: 8
IPT: 2
Material
Properties
WT: 8
WT: 40
CT: 16
IPT: 8
5 Define
Structural
Requirements
CT: 40
IPT: 24
9
Develop
FEM
WT: 16
A
CT: 40
IPT: 32
8
Loads
Analysis
I
CT: 16
IPT: 4
Reformat
Drawings and
Models
I
I
WT: 104
CT: 16
IPT: 4
Global Loads
Environment
24
4
24
8
12
A
4
2
10
SSL
Analysis
CT: 16
IPT: 8
40
24
40
32
40
24
8
2
SSL
Review
CT: 8
IPT: 4
11 Create
Manufacture
Plan
CT: 24
IPT: 16
to 1, 4, 5, 8, 9,
or 10
16
8
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8
4
8
4
8
16
8
16
4
Manufact.
Review
CT: 8
IPT: 4
40
16
16
4
12
Develop
Report
CT: 40
IPT: 12
I
WT: 32
to 1, 4, or 11
24
16
8
4
40
24
Final
Review
40
32
104
Report and
Presentation
CT: 8
IPT: 4
to ANYWHERE
40
12
32
8
4
Total CT:392 hr (9.8 wks)
Total IPT: 178 hr (4.5 wks)
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Value Assessment
•
Identify NVA tasks
•
Identify (and verify) types of value creation, e.g:
•  V1. Definition of End Product with desired Functional Performance
•  V2. Definition of Processes to Deliver Product
•  V3. Reduction of Risks and Uncertainties
•  V4. Form of Final Output – to be compatible with downstream
processes
•
Identify NVA information flows
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Example with Value Assessments
NVA
Requirements
and Constraints
Global Aero.
Environment
1
Choose
Configuration
Config
Review
I
WT: 12
CT: 24
IPT: 8
CT: 4
IPT: 2
Value Key:
CT: 40
IPT: 24
4 Create
Mechanical
Drawings
NVA
Non-valueadded task
Bad
Incorrect
Informaiton
Form
Badly Formatted
Informaiton
24
8
2 Create
Moldline
Drawings
CT: 40
IPT: 24
Information
Gathering
CT: 24
IPT: 4
6
Weight
Analysis
I
CT: 8
IPT: 4
3
Aerodyn.
Analysis
Review
CT: 8
IPT: 2
Form
7
Stability
Analysis
CT: 40
IPT: 32
NVA
Drawing
Material
Properties
WT: 8
WT: 40
CT: 16
IPT: 8
5 Define
Structural
Requirements
CT: 40
IPT: 24
9
Develop
FEM
WT: 16
Bad
Bad
A
CT: 40
IPT: 32
8
Loads
Analysis
I
CT: 16
IPT: 4
Reformat
Drawings and
Models
I
I
WT: 104
CT: 16
IPT: 4
Global Loads
Environment
12
24
4
4
2
Product or Process
Spec. Value
40
24
40
32
40
24
8
2
8
4
8
16
8
16
4
40
16
40
24
16
4
40
32
104
Risk / Uncertaintly
Reduction Value
Enabling Task
Should add
Formatting value
but doesn't
A
10
SSL
Analysis
CT: 16
IPT: 8
SSL
Review
CT: 8
IPT: 4
11 Create
Manufacture
Plan
CT: 24
IPT: 16
to 1, 4, 5, 8, 9,
or 10
16
8
web.mit.edu/lean
8
4
Manufact.
Review
CT: 8
IPT: 4
12
Develop
Report
CT: 40
IPT: 12
Form
I
WT: 32
to 1, 4, or 11
24
16
8
4
Final
Review
Report and
Presentation
CT: 8
IPT: 4
to ANYWHERE
40
12
32
8
4
Total CT:392 hr (9.8 wks)
Total IPT: 178 hr (4.5 wks)
©Massachusetts Institute of Technology McManus- 032603 17
4.0 The Seven Info-Wastes
1. Over-production
Creation of unnecessary data and information;
Information over-dissemination; Pushing, not pulling, data
2. Inventory
Lack of control; Too much in information;
Complicated retrieval; Outdated, obsolete information
3.Transportation
Information incompatibility; Software incompatibility;
Communications failure; Security issues
4. Unnecessary Movement
Lack of direct access;Reformatting
5. Waiting
Late delivery of information;
Delivery too early (leads to rework)
6. Defective Products
Haste; Lack of reviews, tests, verifications;
Need for information or knowledge,data delivered
7. Processing
Unnecessary serial production; Excessive/custom
formatting; Too many iterations
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©Massachusetts Institute of Technology McManus- 032603 18
Eliminating Waste - Best Practices
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Eliminating Time Waste
•  Clear external constraints
•  Assure the availability of information
•  Establish a Takt time
•
Eliminating Non-Value-Added Tasks
•  Monuments
•  Unnecessary Documents and Formatting
•  Unnecessary or Underutilized Analyses
•  Unnecessary or Inefficient Reviews and Approvals
•  Unnecessary Motion
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©Massachusetts Institute of Technology McManus- 032603 19
Future State Example
Requirements
and Constraints
1
Choose
Configuration
Global Aero.
Environment
Config
Review
3
Aerodyn.
Analysis
2 Create
Moldline
Drawings
4 Create
Mechanical
Drawings
Reformat
Drawings and
Models
Mech Design
Review
Material
Properties
9
Develop
FEM
7
Stability
Analysis
10
SSL
Analysis
8
Loads
Analysis
6
Weight
Analysis
5 Define
Structural
Requirements
Week One
Global Loads
Environment
Week Two
Week Three
Decide
Iteration
Path
YES
A
11 Create
Manufacture
Plan
12
Develop
Report
Integrated
Review
Iterate?
NO
Report and
Presentation
Week Four
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©Massachusetts Institute of Technology McManus- 032603 20
A
5.0 Improvement Hueristics
•
The LEM
•
Millard’s Value Stream Analysis Hueristics
•
Collocation, boundary objects, and shared experiences
•
A few good books
•
Some radical ideas
Ideas to help you improve your situation
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©Massachusetts Institute of Technology McManus- 032603 21
Ideal State Example
Requirements
and Constraints
Choose
Configuration
Global Loads
Environment
and Matl. Props
Initial
Integrated
Mechanical
Design/Analysis
Integrated
Review
Final
Integrated
Mechanical
Design/Analysis
Develop
Design-to
Package
Aerodynamic
and Stability
Analysis
Global Aero.
Environment
Week One
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Week Two
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Plan for PDVSM Manual
•
Today:
Alpha Release
Early Reviewer Lunch
•
Soon:
Reviewer Feedback
•
Now-April: Identify test sites
•
May-June: Alpha Tests
•
July:
Revisions
•
August:
1.0 Product Release
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