A Tool to Move Forward With

A Tool to Move Forward With
Value Stream Mapping A Tool to Move Forward With Welcome to Presented by Bob Forder

'Life isn't about how to survive the storm, but how to dance in the rain'

ASK YOURSELF THESE THREE QUESTIONS
Why a Value Stream Map? If you don’t know where you are at – How do you know how to get to where you want to be. ASK YOURSELF THESE THREE QUESTIONS Where am I today? Where do I want to be Tomorrow? How Do I get There?

What is a “Value Stream”
The steps involved in creating an OUTPUT for an Internal or an External Customer Creating a report for your Boss Creating a Purchase Order Creating an Invoice to send to a Customer Installing a new PC for a User Making a Mould for the Foundry to Pour Machining a Part Assembling Sub Components into Finished Goods for Sale

Typical Data Requirements
Customer Data: Manufacturing Data: Who The Number of processes in the Value Stream Customer requirements per year The Name of each process in the Value Stream Piece Size Number of Operators per process per shift Shipping method (Truck, Train, Plane etc…) Number of Machines per process Frequency of shipments Machine Down time (OEE) Supplier Data: Number of shifts Machine time per cycle What they supply Total Cycle Time Shipping Method (Truck, Train, Plane etc…) Pieces per cycle Frequency of Shipments Load / Unload time (operator) Location Pieces per day Piece size Time per setup up Pallet size Number of set ups per day How orders are placed (Electronic, fax, phone etc…) Total Setup time Production Data: Scrap per day per process How do you schedule the processes (MRP, MRPII, ERP, Spreadsheets, etc…) Amount of Inventory before each process. Number of shifts per day Hours per shift Number of breaks per shift Duration of each break Total available time to produce Takt Time (Time required by customer to produce each part) How do you communicate schedule to processes (production schedule, dispatch list, backlog report etc…)

MAPPING ICONS Kanban Path Kanban Post Supermarket Kanban arriving
in batches Signal Kanban MAX 50 PCS First-In First-Out Flow FIFO Withdrawal Kanban Pull ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Process Kaizen Production Kanban Leveling

Mapping Icons

MAPPING ICONS Current- State Drawing I I I Outside Source or Customer
Pr. Control or Customer Electronic ABC Mfg. Information Flow MRP Truck Manual Tue & Shipment Information Flint Assy. Fri Flow 4/day Stamping Assembly I I I ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Inventory (incl. count & time) 2 Shifts 2 Shifts Manufacturing Cycle Time Cycle Time C/O Time C/O Time Process (or a Material Department) Movement via PUSH Data Box

CURRENT-STATE DRAWING
Product Family Understand how the business enterprise currently operates Current- State Drawing * Look at Material and Information Flows * Draw using standardized icons Future-State Drawing * Start with the “door to door” flow * Walk the flow & get actuals ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ • no standard times • draw by hand Work Plan and Implementation

LET’S MAKE A VALUE STREAM MAP
You are the Acme Stamping Company

“Acme Stamping” Data Set
Acme Stamping Company produces several components for vehicle assembly plants. This case concerns one product family: a steel instrument-panel bracket subassembly in two types: one each for left-hand and right-hand drive versions of the same automobile model. These components are sent to the State Street Vehicle Assembly Plant (the customer). Customer Requirements: 18,400 pieces per month 12,000 per month of type “LH” 6,400 per month of type “RH” Customer plant operates on two shifts Palletized returnable tray packaging with 20 brackets in a tray and up to 10 trays on a pallet. The customer orders in multiples of trays. One daily shipment to the assembly plant by truck Work Time: 20 days in a month Two shift operation in all production departments Eight hours every shift, with overtime if necessary Two 10-minute breaks during each shift Manual processes stop during breaks Unpaid lunch

T.T. = TAKT TIME Synchronizes Pace of Production
to Match Pace of Sales Rate for producing a product, and its components, based on sales rate. Your Operating Time per Shift T.T. = Customer Requirement per Shift 27,600 sec ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ = 60 sec 460 pieces 60 sec. 60 sec. 60 sec.

18,400 parts/month / 20 days/month = 920 parts per day
Takt Time = 60 Seconds 18,400 parts/month / 20 days/month = 920 parts per day 920 Parts per day / 2 Shifts = 460 Parts per shift 2 shifts per day / 2 = 1 8 hours per shift = 8 * 60 Minutes per hour = 480 minutes * 60 Seconds per minute = seconds minute breaks = 2 * 10 * 60 = 1200 seconds 28, = 27,600 seconds available to make parts 27,600 Available Seconds / 460 Parts per Shift Required Equals 60 seconds per part or a Takt Time (TT) of 60Sec. ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Production Processes:
Acme’s process for this product family involves stamping a metal part followed by welding and subsequent assembly. The components are then staged and shipped to the vehicle assembly plant on a daily basis. Switching between type “LH” (left hand drive) and type “RH” (right hand drive) brackets requires a 1-hour changeover in stamping, and 10-minute fixture change in the welding processes. Steel coils are supplied by Michigan Steel Company. Deliveries are made to Acme on Tuesdays and Thursdays. Acme Production Control Department: Receives State Street’s 90/60/30 day forecasts and enters them into MRP Acme issues a 6-week forecast to Michigan Steel Co. via MRP Secures coil steel by weekly faxed order release to Michigan Steel co. Receives daily firm order from State Street Generates MRP based weekly departmental requirements based upon customer orders, WIP inventory levels, F/G inventory levels, and anticipated scrap and downtime Issues weekly build schedules to Stamping, Welding, and Assembly processes Issues daily shipping schedule to Shipping Department

So… We always start with the Customer and a “Bart Head”
Takt Time = 60 So… We always start with the Customer and a “Bart Head” What do we know about the Customer? ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Takt Time = 60 ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Process Information: All processes occur in the following order and each piece goes through all processes. 1. Stamping (The press makes parts for many Acme products and is called a shared resource) Automated 200 ton press with coil (automatic material feed) Cycle time: 1 second (60 pieces per minute) Changeover time: 1 hour (good piece to good piece) Machine reliability: 85% Observed Inventory 5 days of coils before stamping 4,600 pieces of type “LH” finished stampings 2,400 pieces of type “RH” finished stampings

2. Spot-Weld Workstation #1
(Dedicated to this product family) Manual process with one operator Cycle time: 39 seconds Changeover time: 10 minutes (fixture change) Reliability: 100% Observed Inventory: 1,100 pieces of type “LH” 600 pieces of type “RH”

3. Spot Weld Workstation #2
(Dedicated to this product family) Manual process with one operator Cycle time: 46 seconds Changeover time: 10 minutes (fixture change) Reliability: 80% Observed Inventory: 1,600 pieces of type “LH” 850 pieces of type “RH”

4. Assembly Workstation #1
(Dedicated to this product family) Manual process with one operator Cycle time: 62 seconds Changeover time: none Reliability: 100% Observed Inventory: 1,200 pieces of type “LH” 640 pieces of type “RH”.

5. Assembly Workstation #2
(Dedicated to this product family) Manual process with one operator Cycle time: 40 seconds Changeover time: none Reliability: 100% Observed Finished Goods Inventory in Warehouse: 2,700 pieces of type “LH” 1,440 pieces of type “RH” 6. Shipping Department Removes parts from finished goods warehouse and stages them for truck shipment to the customer

So… Let’s Start Building the Process starting with the first process
Takt Time = 60 So… Let’s Start Building the Process starting with the first process The Triangle with the “I” is for your observed Inventory before each process The Box is to Identify a process ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

So… What do we know about the Process and what do we want to know?
Takt Time = 60 So… What do we know about the Process and what do we want to know? ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Takt Time = 60 ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Takt Time = 60

Takt Time = 60 ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

CURRENT STATE I ACME PC&L MICH. STEEL COILS STATE STREET 20 days / mo
2 shifts – 8hrs (2) 10 min breaks / shift ACME PC&L MICH. STEEL COILS 18400 pcs/mo 12000 LH 6400 RH 2 SHIFTS Min. pack : 20 STATE STREET 6 wk. f’cst weekly fax daily order 90/60/30 day f’cst MRP Daily Ship Schedule Tues/ Th WEEKLY SCHEDULE 1/day C/T: 1 sec C/O: 1 hr Rel: 85% Multiple Products Stamping Weld I Weld II ASSM I Shipping ASSM II I C/T: 39 sec C/O: 10 min Rel: 100% Dedicated C/T: 46 sec Rel: 80% C/T: 62 sec C/O: 0 C/T: 40 sec 5 days 4600 LH 2400 RH 7000 T (7000/920) = 7.6 d (1700/920) = 1.8 d 1100 LH 600 RH 1700 T 1600 LH 850 RH 2450 T 1200 LH 640 RH 1840 T 2700 LH 1440 RH 4140 T (2450/920) = 2.7 d (1840/920) = 2 d (4140/920) = 4.5 d Lead Time 5 days 1 sec 7.6 days 39 sec 1.8 days 46 sec 2.7 days 62 sec 2 days 40 sec 4.5 days 23.6 days Process Time 188 sec

OXOX Future State I MICH. STEEL COILS ACME PC&L STATE STREET MRP DAILY
6 wk. f’cst Daily fax MICH. STEEL COILS ACME PC&L MRP 600 LH 320 RH Stamping Shipping 200T ASSEMBLY 2 Weld LH RH 20 BIN BATCH 300 LH 160 RH coil DAILY C/T < 60 sec daily order 90/60/30 day f’cst 18400 pcs/mo 12000 LH 6400 RH 2 SHIFTS Min. pack : 20 STATE STREET 1/day OXOX Daily Order coils C/T: 1 sec C/O: 1 hr Rel: 85% Multiple Products C/T: 46 sec C/O: 10 min Rel: 80% Total work = 85 sec C/T: 56 sec C/O: 0 Rel: 100% Total work = 102 sec Reduced lead time by days Lead Time 1.5 days 1 sec 85 sec 0.75 days 102 sec 5.25 days Process Time 188 sec

20 OXOX Future State II MICH. STEEL COILS ACME PC&L STATE STREET MRP
6 wk. f’cst Daily fax MICH. STEEL COILS ACME PC&L MRP coil DAILY Total work < 168 daily order 90/60/30 day f’cst 18400 pcs/mo 12000 LH 6400 RH 2 SHIFTS Min. pack : 20 STATE STREET 20 OXOX Daily Order C/T: 1 sec C/O: 1 hr Rel: 85% Multiple Products Shipping WELD + ASSEMBLY 3 LH RH C/T: 56 sec C/O: 0 Rel: 98% Total work = 168 sec 600 LH 320 RH Stamping 200T BATCH BIN 1.5 days 1 sec Lead Time 168 sec 4.5 days Process Time 169 sec Weld c/o Weld rel >98% 1/day

20 OXOX Future State III MICH. STEEL COILS ACME PC&L STATE STREET MRP
6 wk. f’cst Daily fax MICH. STEEL COILS ACME PC&L MRP coil DAILY Total work < 168 daily order 90/60/30 day f’cst 18400 pcs/mo 12000 LH 6400 RH 2 SHIFTS Min. pack : 20 STATE STREET 20 OXOX Daily Order C/T: 1 sec C/O: 1 hr Rel: 85% Multiple Products Shipping WELD + ASSEMBLY 3 LH RH C/T: 56 sec C/O: 0 Rel: 98% Total work = 168 sec 600 LH 320 RH Stamping 200T BATCH BIN 1.5 days 1 sec Lead Time 168 sec 4.5 days Process Time 169 sec Weld c/o Weld rel >98% 1/day

WHAT WOULD AN INFORMATION OR AN OFFICE TYPE MAP LOOK LIKE?

YEARLY VALUE STREAM PLAN Value Stream Objective
YEARLY VALUE STREAM PLAN Date: 06/26/2008 Prepared by: Bob Forder Value Stream Chem Lab Year: MONTHLY SCHEDULE Plant Level Objective V.S. Loop Value Stream Objective Goal 1 2 3 4 5 6 7 8 9 10 11 12 Person Resp. Comments Move Chem Lab VS1 Facilitate Chem Lab Move Move Chem Lab by 4th week in July X Lori Palmateer, Bob Forder, Ian Murray Chem Lab move to new location in Foundry. Creates the need to facilitate Material and Information movement as well as relation of Grinders and a procedure for use. Move Physical Information Physical Move of Job Cards, Samples and Certs ALL We were looking at a Vacuum Tube system, however after meeting now looking at creation of Formal and Informal Milk Runs Move Electronic Information Electronic Move of Certs and Results Lori, Jeff, Brian, Kevin, Gail and Scan to Remove old Office Tear down old office by 1st week in August Ian, Bob Remove old block walls from existing Chem Lab Office Establish Location and procedures for Grinding Move grind operation and create procedure for same Lori, Azaz, Jeff The grinders have to move with the office, we need to determine what the short term and long term solutions are. Weekly Equipment Calibration VS2 Streamline the weekly function of calibration of equipment Reduce the time taken to calibrate the spectrometer as well as other equipment by at least 50% Present procees time estimated between 4 and 6 hours Standardization Backlogs on Mondays Increase area availability on Mondays Add resources to back fill existing Technician to free up processing time in the Lab Area during the Monday Standardization process. Lori, Jeff, Kevin Study Standardization process and find areas to reduce time and increase availability Off Shift Samples and Certs VS3 Increase area availability during offshift and peaks Train personell to help as required and perform functions during off shift times Lori, Jeff, Kevin, Supervisors Training people to help in this function will help with day to day functions as well as backfill during peak periods.

Thank you … Remember that this was just a quick taste of How to Build a VSM, How to Read a VSM and What to do with a VSM Bob Forder 5S / Lean Coordinator at Deloro Stellite Inc., Belleville Chairman of the Quinte Manufacturers Association Owner and Trainer for Learning To See Lean

The 5S numbers game.

These sheet represents our current work place.
Please do not look at the sheets until asked to do so. Our job during a 20 second shift, is to strike out the numbers 1 to in correct sequence. Example: The team score will be represented by the lowest individual score achieved. The sheets will be handed out face down and I will keep time. Each person will call out their individual scores Turn over sheet 1 Now. Handout sheets after point 5 when I say sheets will be handed out face down. After 20 seconds and everyone has hollered out their score ask “Are you happy with the score ??”

48 87 45 30 33 72 3 27 69 51 21 24 75 57 18 9 6 78 54 36 60 63 12 15 81 42 39 66 84 90 2 53 68 80 74 77 86 62 29 65 5 41 20 23 56 32 35 44 89 8 83 50 47 26 11 17 38 14 59 71 Are you happy with the score ?? Why could you not achieve a better score? What do you think needs to happen to help you better your score? 31 64 49 61 34 28 54 7 40 16 52 58 76 10 22 88 73 1 85 82 4 43 25 37 13 19 67 79 46 70

TEAM SCORE ___________

For our first action, we are going to implement 5S in this area.
The first step of this is “Sort” and so we have removed from the area all the numbers from 50 to 90 which are not needed. Same rule applies. Strike out numbers 1 to 49 in sequence during a 20 second shift. Turn over the 2nd sheet now! OK, so lets do a 5S and sort

48 45 30 33 3 27 21 24 18 9 6 36 12 15 42 39 2 29 5 41 20 23 32 35 44 8 47 26 11 17 38 14 What are their scores now? What helped to increase the score. What needs to happen to make this even better 31 49 34 28 7 40 16 10 22 1 4 43 25 37 13 19 46

Having achieved some improvement, we now need to move onto the next step ”Set In Order”.
We have installed some racking, and we have organized the items so that with Number 1 in the bottom left hand corner, the numbers are located from left to right and bottom to top - examples 1 in the bottom left, 2 in the middle, and 3 in the top left. Same rules apply 20 second shift, lowest individual score equals team score etc… Turn over the 3rd Sheet now!

48 45 30 33 3 27 21 24 18 9 6 36 12 15 39 42 2 29 5 41 20 23 32 35 44 8 47 26 11 17 38 14 What are your scores now. Why did this help improve your score? 31 49 34 28 7 40 16 10 22 1 4 43 25 37 13 19 46

Having now made a significant step forward, we must now “Shine” and “Standardize”.
Since we are dealing with numbers 1 to 49 in sequence, it seems logical to re-organize them in a standard way that makes the completion of the work task as easy as possible. So we have “SHINE” the area by making the area presentable and tidy, we have Standardized by making all numbers the same size and font and organizing them in a fashion that is easier to follow. This should ensure that everyone is able to complete the task (and therefore produce a team score of 49.) Turn over the 4th Sheet now!

Numbers from 1 to 49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Who did not get 49? Why so much better Can we organize our work place to resemble this? 41 42 43 44 45 46 47 48 49

Turn over the 5th Sheet Now!
To show respect for Standards it is necessary to make the “management” of the area visual. Returning to our original work area, we have for this assignment two numbers missing. We cannot complete the task without these numbers - so first we have to find them. I will start a clock running and every 20 seconds, I will tell you how many “shifts” you have been down looking for the appropriate numbers. Turn over the 5th Sheet Now! Why is standards and standardized work so important to our work place? Could it be to help the Quality of Work that we put out and maybe to help make the quality built in so to say?

48 87 45 30 33 72 3 27 69 51 21 24 75 57 9 6 78 54 36 60 63 12 15 81 39 66 84 90 2 53 68 80 74 77 86 62 29 65 5 41 20 23 56 32 35 44 89 8 83 50 47 26 11 17 38 14 59 71 42 & 18 31 64 49 61 34 28 54 7 40 16 52 58 76 10 22 88 73 1 85 82 4 43 25 37 13 19 67 79 46 70

Now how much easier would it be to find the quality problems with the system we had earlier? Let’s try it. Turn over the 6th Sheet now!

Numbers from 1 to 49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Did everyone get the missing numbers… Obvious isn’t it. 41 43 44 45 46 47 48 49

A Tool to Move Forward With

Similar presentations

Presentation on theme: "A Tool to Move Forward With"— Presentation transcript:

Similar presentations

About project

Feedback

Log in

Auth with social network:

A Tool to Move Forward With

Similar presentations

Presentation on theme: "A Tool to Move Forward With"— Presentation transcript:

Similar presentations

About project

Feedback