Value Stream 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 | Value Stream Mapping

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 | Value Stream Mapping

Course Outline Value Stream Mapping

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

What are Value Stream Maps? Value Stream Mapping

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 Value Stream Mapping

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| 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 Value Stream Mapping What Are Value Stream Maps| Types

Identifying Value Streams Value Stream Mapping

» 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 | 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) Value Stream Mapping How to Map the Value Stream | What to Map Idea

Map Current State Value Stream Mapping

» Use pencil, paper, Post-it Notes » Why not to start with a computer??? Value Stream Mapping 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 Value Stream Mapping How to Map the Value Stream | What Type of Map??

» Traditional Mapping Icons Value Stream Mapping How to Map the Value Stream | Tools

» Several TYPES of maps to use » Swim Lane VSMs Value Stream Mapping 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 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 » 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 How to Map the Value Stream | Drawing the Current State map Idea

Map Future State Value Stream Mapping

» Consider the ideas that came up during the 1 st mapping process » Also consider these guidelines Eliminate/Reduce Non-Value Adding Steps 2.Produce to the takt time 3.Develop continuous flow whenever possible 4.Use “supermarkets” to control productions where continuous flow is no possible 5.Try to schedule at only one production process (pacemaker process) 6.Distribute part variety evenly over time at the pacemaker process 7.Create a “pull” by releasing small increments of work at the pacemaker process 8.Develop ability to “make every part every day” Value Stream Mapping 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 Value Stream Mapping How to Map the Value Stream | Drawing the Future State map

Let’s try our hand at it! Value Stream Mapping

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 Value Stream Mapping Quick Reference Sheet Swim Lane VSM Guidelines for improvements 1.Reduce/Eliminate Non-Value Adding Steps 2.Produce to the takt time 3.Develop continuous flow whenever possible 4.Use “supermarkets” to control production where continuous flow is not possible 5.Try to schedule in only one production process (pacemaker process) 6.Distribute part variety evenly over time at the pacemaker process 7.Create a “pull” by releasing small increments of work at the pacemaker process 8.Develop ability to “make every part every day” Make it happen – without this step the whole thing is a waste Ideas More Ideas