Value
Stream
Mapping
Introductions
& Objectives
Value Stream Mapping
Introductions and Objectives |
Introductions
» Who are you?
» How long with YESCO?
» Something that few in the group know
about you?
Value Stream Mapping
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.
Value Stream Mapping
Course
Outline
Value Stream Mapping
Course Outline|
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What are Value Streams & Value Stream Maps?
Identifying Value Streams
Mapping The Current State
Creating & mapping The Future State
Value Stream Mapping
What are
Value Stream Maps?
Value Stream Mapping
What Are Value Streams| Definition
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.
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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
Value Stream Mapping
What Are Value Stream Maps| 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
Value Stream Mapping
What Are Value Stream Maps| Types
“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
Value Stream Mapping
Identifying
Value Streams
Value Stream Mapping
How to Map the Value Stream | Choosing a Product Family
» 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
Value Stream Mapping
How to Map the Value Stream | What to Map
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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)
Idea
Value Stream Mapping
Map
Current State
Value Stream Mapping
How to Map the Value Stream | Tools
» Use pencil, paper, Post-it Notes
» Why not to start with a computer???
» 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
Value Stream Mapping
How to Map the Value Stream | What Type of Map??
» Several TYPES of maps to use......
» Traditional VSMs
Value Stream Mapping
How to Map the Value Stream | Tools
» Traditional
Mapping Icons
Value Stream Mapping
How to Map the Value Stream | What Type of Map??
» Several TYPES of maps to use......
» Swim Lane VSMs
Value Stream Mapping
How to Map the Value Stream | Drawing the Current State 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...
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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
Value Stream Mapping
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
Idea
» 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”
Value Stream Mapping
Map
Future State
Value Stream Mapping
How to Map the Value Stream | Drawing the Future State map
How will the Future State be different from the Current State?
» Consider the ideas that came up during the 1st mapping process
Ideas
» Also consider these guidelines......
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Eliminate/Reduce Non-Value Adding Steps
Produce to the takt time
Develop continuous flow whenever possible
Use “supermarkets” to control productions where continuous flow is no possible
Try to schedule at only one production process (pacemaker process)
Distribute part variety evenly over time at the pacemaker process
Create a “pull” by releasing small increments of work at the pacemaker process
Develop ability to “make every part every day” More
Ideas
Value Stream Mapping
How to Map the Value Stream | Drawing the Future State map
» 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
Value Stream Mapping
Let’s try
our hand at it!
Value Stream Mapping
Quick Reference Sheet
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.
Swim Lane VSM
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
Guidelines for improvements
Kaizen Bursts help you capture improvement ideas
while mapping
Ideas
Tools to use include:
Pencil, paper, eraser, stopwatch, Going to the Gemba,
teams, your ideas
Traditional VSM
1.
2.
3.
4.
5.
6.
7.
8.
More
Reduce/Eliminate Non-Value Adding Steps
Ideas
Produce to the takt time
Develop continuous flow whenever possible
Use “supermarkets” to control production where continuous
flow is not possible
Try to schedule in only one production process (pacemaker
process)
Distribute part variety evenly over time at the pacemaker
process
Create a “pull” by releasing small increments of work at the
pacemaker process
Develop ability to “make every part every day”
Make it happen – without this step the whole thing
is a waste
Value Stream Mapping