1. Value Stream Mapping AGENDA Introduction to mapping
Creating a Current State Map
Introduction To Lean Techniques
Creating a Future State Map
Using a Map as a basis for Tactical Implementation Planning

2. Future State Value Stream Mapping
THE 9 KEY QUESTIONS :
1. What are the customer requirements
2. How to apply Continuous Flow Processing
3. Which process is the pacemaker
4. How to control upstream processes
5. What size supermarkets (shop stock) are required
6. Is it sequential or fill-up pull
7. Where to level production
8. At what frequency will kanban be released
9. What further improvements can be made
Talk through the slide adding personal experience.

3. Creating a Future State Value Stream Map
THE 7 STEPS
Customer Requirements
Draw Process Steps
Process Data
Inventory
Material Flow: Supplier to Manufacturer & Manufacturer to Customer
Information Driving Flow & Internal Material Flow
Manufacturing Lead Time & Processing Time

4. Icons for use in Future State
FIFO I
Supermarket with Prod Card & Withdrawal card
First In First Out sequence flow
300 pieces 1Day
XYZ corporation
Kanban Post
Pull Symbol
Inventory
Outside sources
Mon + Wed
CHANGEOVER
Signal Kanban Min & Max
Supermarket
Kaizen lightening burst
Truck Shipment
Supermarket with Prod Card
PUSH arrow
Production Control
Information System VSM Symbols
These are icons used for design of future state
Talk through the slide adding personal experience.
abc
OXOX 4
Production Control
Electronic information flow
Level loading Production
Manual Information flow
Sequenced-Pull Ball
Ref.ppt

5. Go to white board and change current state to future state.
Ask the delegates to draw it with you

6. Production Lead Time = 26.6 days
Current State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
16 pieces/ day
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
1 x Daily
Daily
shipping
plan I I I I I I
Inventory (cont....)
Participants to read inventory counts from data sheet.
Repeat each item as you write it on the whiteboard.
Encourage participants to avoid average data.
Draw inventory triangle.
Record inventory quantity.
Label the map in the lower right-hand corner.
Stamping
Spot weld # 1
Spot weld # 2
Assembly # 1
Assembly # 2
Shipping
5 days
150 A1
24 A2
42 A1
6 A2
16 A1
18 A2
42 A1
6 A2
27 A1
14 A2
10 T
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
Cycle time= 39 minute
Change over=10 min.
Uptime =100%
1 x
Cycle time= 46 minute
Change over=10 min.
Uptime =80%
1 x
Cycle time= 62 minute
Change over=0 min.
Uptime =100%
1 x
Cycle time= 40 minute
Change over=0 min.
Uptime =100%
1 x
Production Lead Time = 26.6 days
Processing time = 188 mins
5 days
10.9 days
3 days
2.1 days
3 days
2.6 days
1 minute
39 minute
46 minute
62 minute
40 minute
Slug Brackets Stamping
Currents State Map
Date : .

7. Production Lead Time = 26.6 days
Add Takt Calculation
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
MRP
16 pieces/ day
320 pieces/ month
200 A1
120 A2
500 ft coils
Weekly plan
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
2 shifts
Tuesday
and
Thursday
Pack size = 1 x
1 x Daily
Daily
shipping
plan I I I I I I
Highlight the takt calculation added previously.
Draw a supermarket icon and explain the potential benefits.
Stamping
Spot weld # 2
Spot weld # 2
Assembly # 2
Assembly # 1
Shipping
5 days
150 A1
24 A2
42 A1
6 A2
16 A1
8 A2
42 A1
6 A2
27 A1
14 A2
10 T
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
Cycle time= 39 minute
Change over=10 min.
Uptime =100%
1 x
Cycle time= 46 minute
Change over=10 min.
Uptime =80%
1 x
Cycle time= 62 minute
Change over=0 min.
Uptime =100%
1 x
Cycle time= 40 minute
Change over=0 min.
Uptime =100%
1 x
Production Lead Time = 26.6 days
Processing time = 188 mins
5 days
10.9 days
3 days
2.1 days
3 days
2.6 days
1 minute
39 minute
46 minute
62 minute
40 minute
Slug Brackets Stamping
Currents State Map
Date : .

8. Where is Continuous Flow Possible?
DRAW ON FLIP CHART
62 min.
57.5 min.
Takt
46 min.
40 min.
39 min.
We need to understand where continuous flow is possible.
Draw the balance chart showing each of the processes.
Circle the stamping and explain that because the stamp services many parts it cannot become part of the dedicated flow.
1 min.
Stamp
SW 1
SW 2
Assy. 1
Assy. 2

9. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
1 x Daily
Daily
shipping
plan I I I I I I
Add the bits as you go. Explain each one.
Stamping
Spot weld # 2
Spot weld # 2
Assembly # 2
Assembly # 1
Shipping
5 days
150 A1
24 A2
200 A1
6 A2
16 A1
8 A2
42 A1
6 A2
27 A1
14 A2
10 T
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
Cycle time= 39 minute
Change over=10 min.
Uptime =100%
1 x
Cycle time= 46 minute
Change over=10 min.
Uptime =80%
1 x
Cycle time= 62 minute
Change over=0 min.
Uptime =100%
1 x
Cycle time= 40 minute
Change over=0 min.
Uptime =100%
1 x
Production Lead Time = 26.6 days
Processing time = 188 mins
5 days
10.9 days
3 days
2.1 days
3 days
2.6 days
Slug Brackets Stamping
Currents State Map
Date : .

10. Where is Continuous Flow Possible?
DRAW ON FLIP CHART
62 min.
57.5 min.
Takt
46 min.
39 min.
40 min.
We need to understand where continuous flow is possible.
Draw the balance chart showing each of the processes.
Circle the stamping and explain that because the stamp services many parts it cannot become part of the dedicated flow.
Can we flow between the 2 spot weld stations, can they pass parts directly to each other.
1 min.
Stamp
SW 1
SW 2
Assy. 1
Assy. 2

11. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Weekly plan
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
2 shifts
Tuesday
and
Thursday
Pack size = 1
1 x Daily
Daily
shipping
plan I I I I I I
Add the bits as you go. Explain each one.
Both can change at the same time.
Uptime on 2 needs improvement add Kaizen burst.
Stamping
Spot weld # 2
Spot weld # 2
Assembly # 2
Assembly # 1
Shipping
5 days
150 A1
24 A2
200 A1
6 A2
16 A1
8 A2
42 A1
6 A2
27 A1
14 A2
10 T
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
Cycle time= 39 minute
Change over=10 min.
Uptime =100%
1 x
Cycle time= 46 minute
Change over=10 min.
Uptime =80%
1 x
Cycle time= 62 minute
Change over=0 min.
Uptime =100%
1 x
Cycle time= 40 minute
Change over=0 min.
Uptime =100%
1 x
Production Lead Time = 26.6 days
Processing time = 188 mins
5 days
10.9 days
3 days
2.1 days
3 days
2.6 days
Slug Brackets Stamping
Currents State Map
Date : .

12. Where is Continuous Flow Possible?
DRAW ON FLIP CHART
62 min.
57.5 min.
Takt
46 min.
39 min.
40 min.
We need to understand where continuous flow is possible.
The assembly operations are manual we should be able to achieve continuous flow between them?
1 min.
Stamp
SW 1
SW 2
Assy. 1
Assy. 2

13. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
1 x Daily
Daily
shipping
plan I I I I I I
Add the bits as you go. Explain each one.
Explain the saving in lead time.
So far 3.8 days.
Lean thinkers try to establish as much continuous flow as possible.
Stamping
Spot weld # 2
Spot weld # 2
Assembly # 2
Assembly # 1
Shipping
5 days
150 A1
24 A2
200 A1
6 A2
16 A1
8 A2
42 A1
6 A2
27 A1
14 A2
10 T
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
Cycle time= 39 minute
Change over=10 min.
Uptime =100%
1 x
Cycle time= 46 minute
Change over=10 min.
Uptime =80%
1 x
Cycle time= 62 minute
Change over=0 min.
Uptime =100%
1 x
Cycle time= 40 minute
Change over=0 min.
Uptime =100%
1 x
Production Lead Time = 26.6 days
Processing time = 188 mins
5 days
10.9 days
3 days
2.1 days
3 days
2.6 days
Slug Brackets Stamping
Currents State Map
Date : .

14. Where is Continuous Flow Possible?
Ideal No. Of Operators = Total Work Content
Takt Time
e.g.
Ideal No. Of Operators = minutes of work
57.5 minutes Takt
= operators
= 4
= target of 3
We need to understand where continuous flow is possible.
Can we join spot weld to assy. In flow?
What is the total work content?
What does this mean?
Explain that by adding all the process time together it gives us 187 minutes worth of work. Divide this by the Takt of 60 minutes, this equals the ideal number of operators = 3.25
Traditional manpower planners would say we need 4, but 4 would be adding a significant amount of waste into the system. Lean thinkers say 3 and reduce the work content through kaizen. And achieve flow with 3. x

15. Where is Continuous Flow Possible?
DRAW ON FLIP CHART
(55 X 3) + 22 = 187 minutes
57.5 min.
Takt
Takt 55 55 55
Cycle Time
16 min.
18 min.
SW 2
25 min.
Assy. 2
Assy. 1
We need to understand where continuous flow is possible.
What we would like is to give each operator 55 minutes of work each. This would be achievable with a good kaizen process in the company.
This should be possible because we spend a lot of time fetching bits.
Reasons for a reduced cycle time can be :-
Allows some time for inefficiency because cycling to takt can be dangerous in a production system that shows a degree of instability.
it can be the start of the kaizen cycle for the reduction of man hours
can be an indication of the flexibility in the system.
39 min.
30 min.
37 min.
22 min.
1 min.
SW 2
SW 1
Assy. 1
Assy. 2
Stamp

16. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
1 x Daily
Daily
shipping
plan I I I I I I
Add the bits as you go. Explain each one.
We need to also look at change over ( kaizen burst)
Stamping
Spot weld # 2
Spot weld # 2
Assembly # 2
Assembly # 1
Shipping
5 days
150 A1
24 A2
200 A1
6 A2
16 A1
8 A2
42 A1
6 A2
27 A1
14 A2
10 T
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
Cycle time= 39 minute
Change over=10 min.
Uptime =100%
1 x
Cycle time= 46 minute
Change over=10 min.
Uptime =80%
1 x
Cycle time= 62 minute
Change over=0 min.
Uptime =100%
1 x
Cycle time= 40 minute
Change over=0 min.
Uptime =100%
1 x
Production Lead Time = 26.6 days
Processing time = 188 mins
5 days
10.9 days
3 days
2.1 days
3 days
2.6 days
Slug Brackets Stamping
Currents State Map
Date : .

17. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
Daily
shipping
plan
1 x Daily
Weld+ assy. I
Add the bits as you go. Explain each one.
Rub out all the other stuff so it looks like this.
We also decided to have 2 days worth of finished goods.
Stamping is not part of the flow so we need a supermarket to schedule it.
Stamping
Shipping
5 days
TT= 60 minute
10 T
C/T=55 min
Work content
To 55 min.
2 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
Target 3 Ops
Slug Brackets Stamping
Currents State Map
Date : .

18. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
Daily
shipping
plan 1
1 x Daily
Weld+ assy. I
Add the bits as you go. Explain each one.
We need bits with the operators so that they can add value more frequently. To achieve this we can introduce ‘material handlers’
Explain material handlers and what they do.
Stamping
Shipping
5 days
TT= 60 minute
10 T
C/T=55 min
Work content
To 55 min.
2 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
Target 3 Ops
Slug Brackets Stamping
Currents State Map
Date : .

19. Drawing a Future State Map
Customer
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
Daily
shipping
plan 1 1
1 x Daily
Weld+ assy. I
Add the bits as you go. Explain each one.
We need bits with the operators so that they can add value more frequently. To achieve this we can introduce ‘material handlers’
Explain material handlers and what they do.
Explain what a production Kanban is.
Explain what a withdrawal Kanban is.
Stamping
Shipping
5 days
TT= 60 minute
10 T
C/T=55 min
Work content
To 55 min.
2 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
Target 3 Ops
Slug Brackets Stamping
Currents State Map
Date : .

20. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
Daily
shipping
plan 1
batch
1 x Daily
Weld+ assy. I
Add the bits as you go. Explain each one.
Explain that it’s not practical for the stamping process for us to produce exactly to kanban requirements because stamping needs a 1 hour change over.
We overcome this by managing the optimum inventory through minimum batch quantities to achieve flow for all the processes that it supplies.
Stamping
Shipping
5 days
TT= 60 minute
10 T
C/T=55 min
Work content
To 55 min.
2 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
Target 3 Ops
Slug Brackets Stamping
Currents State Map
Date : .

21. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
Daily
shipping
plan 1
batch
1 x Daily
Weld+ assy. I
Add the bits as you go. Explain each one.
Explain that at this process we have determined the batch size by introducing the concept of (EPEI) therefore we want every part every day. This then determines the supermarket stock level of 1 days worth but, to be on the safe side we will add half a days worth in case of any problems that may occur until we are fully confidant in the system. The batch kanban tells stamping to change over for the next product.
Write 1 ½ days under the stamping supermarket.
Stamping
Shipping
5 days
TT= 60 minute
10 T
C/T=55 min
Work content
To 55 min.
2 days
delivery trays
1.5 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
Target 3 Ops
Slug Brackets Stamping
Currents State Map
Date : .

22. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pack size = 1
Daily
Shipping plan 1
batch 1 1
1 x Daily 1
Weld+ assy. I
Add the bits as you go. Explain each one.
Shipping takes 46 trays out of the assy. Supermarket each day and prepares (stages) them ready for dispatch. This releases 46 kanbans to assembly.
Sending 46 kanbans back to assembly is not very good.
This way sends us back to working close to a mass production environment again.
What can we do?
Stamping
Shipping
5 days
TT= 60 minute
10 T
C/T=55 min
stage
Work content
To 55 min.
2 days
delivery trays
1.5 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
Target 3 Ops
Slug Brackets Stamping
Currents State Map
Date : .

23. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Weekly fax
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Tuesday
and
Thursday
Pitch = 57.5 mins
Pack size = 1
Daily
Shipping plan 1
OOXXOOXX
batch 1 1 1
1 x Daily 1 2
Weld+ assy. 4 3 I
Add the bits as you go. Explain each one.
Of course we need to level the production onto the assembly process in a sequenced. Assembly only need one kanban at a time and in the right sequence to achieve the customer requirement.
Explain the steps the material handler goes through.
Picks up next kanban at the leveling box
Takes the kanban to assembly to tell them what the next 1 minutes production will be
Picks up the latest 1 minutes worth of completed work (1 pitch worth)
Takes the finished pieces to the supermarket
Explain the load leveling box.
Ask: how long will it be before we become aware of any production problems? 1 minutes this equals our management time frame.
Stamping
Shipping
5 days
TT= 60 minute
10 T
C/T=55 min
stage
Work content
To 55 min.
2 days
delivery trays
1.5 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
Target 3 Ops
Slug Brackets Stamping
Currents State Map
Date : .

24. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
Weekly plan
2 shifts
Daily
Pitch = 57.5mins
Pack size = 1
Daily
Shipping plan 1
OOXXOOXX
batch 1 1
1 x Daily 1
Weld+ assy.
Add the bits as you go. Explain each one.
The next supermarket comes from the supplier. Through negotiations.
Change the requirement to daily plus ½ days worth of comfort stock.
Delivery changes to daily
Stamping
Shipping
TT= 60 minute
10 T
C/T=55 min
stage
Work content
To 55 min.
2 days
delivery trays
1.5
days
1.5 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
Target 3 Ops
Slug Brackets Stamping
Currents State Map
Date : .

25. Drawing a Future State Map
Customer
Coils r us
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
2 shifts
Daily
Pitch = 57.5 mins
Pack size = 1 1
OOXXOOXX
Daily
Shipping plan
batch 1 1
1 x Daily 1
Weld+ assy.
Stamping
Summarise what has happened through the transformation.
Add a new time line and compare the results
Shipping
TT= 60 minute
10 T
C/T=55 min
stage
Work content
To 55 min.
2 days
delivery trays
1.5
days
1.5 days
4 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
5 days
Target 3 Ops
166 minutes
1.5
days
1.5 days
2 days
1 min
165 min
Slug Brackets Stamping
Currents State Map
Date : .

26. Value Stream Mapping Delegates to design own future state map
This is where you need to send the team onto the shop floor to design their own future stae map.

27. Developing an Improvement Plan
Current State Map
Gap
Analysis …
...
Future State Map
Talk through the slide adding personal experience.
WHERE WILL YOU START ?

28. Dividing a Future State Map
Customer
F.A.L.
6 week forecast
30/ 60/ 90 day forecast
Supplier loop
Production Planning
Daily expedite
16 pieces/ day
MRP
320 pieces/ month
200 A1
120 A2
500 ft coils
Takt = 2(480-20)minutes = 57.5 mins
16 pieces
Pitch = 57.5 mins x 1 pieces = 57.5 mins
2 shifts
Daily
Pitch = 57.5 mins
Pack size = 1
Daily
Shipping plan 1
OOXXOOXX
batch 1 1
1 x Daily
Pacemaker loop 1
Weld+ assy.
Stamping
loop
Break the future state map into bite size chunks.
Stamping
Shipping
TT= 60 minute
10 T
C/T=55 min
stage
Work content
To 55 min.
2 days
delivery trays
1.5
days
1.5 days
3 x
Cycle time= 1 minute
Change over=1 hour
Uptime =85%
1 x
SW 2
uptime
SW C/O
5 days
Target 3 Ops
166 minutes
1.5
days
1.5 days
2 days
1 min
165 min
Slug Brackets Stamping
Currents State Map
Date : .

29. Value Stream Mapping AGENDA Introduction to mapping
Creating a Current State Map
Practical Exercise
Introduction To Lean Techniques
Creating a Future State Map
Using a Map as a basis for Tactical Implementation Planning

30. Why Have a Formal Plan to Achieve the future State?
To set the
team
direction
To show a relevant level of detail to those concerned -
NB. each loop will have it’s own execution schedules
within the implementation plan
To encourage regular reviews for signs of QCD problems -
slippage's, early deliveries, continued ownership
To formalise commitment from key people:
Facility Manager Value stream manager
The Unions Manufacturing Engineering
Maintenance Process Engineering
Purchasing
Talk through the slide adding personal experience.
The key elements of a Value Stream’s Implementation plan
are shown in the following example.

31. Example - Tactical Implementation Plan (T.I.P.)
Type of TIP
and Model Line
Level 1
Activity
5C Activity
Responsible
People
Level 2
Detailed
Actions
Timebased
Schedule of
activities
Category
Please see ‘tactical implementation plans’ workshop
Talk through the slide adding personal experience.

32. Summary Use the 7 steps to draw a current state Value Stream Map.
Collect data across a value stream.
Use the 7 steps to draw a current state Value Stream Map.
Use the 9 questions and 7 steps to draw a future state Value Stream Map.
Identify your Material/Information loops.
Decide the order to tackle the loops.
Write the Tactical Implementation Plan
Set objectives for each loop as required to achieve the future state
Set measurable goals for each objective
Use the 9 questions within each loop to set an order of work
Set milestones and write up the plan
Get formal agreement from all concerned
The leader of each work stream should produce their own execution schedule showing how to achieve each goal by it’s milestone.
Talk through the slide adding personal experience.

33. Value Stream Mapping AGENDA Introduction to mapping
Creating a Current State Map
Practical Exercise
Introduction To Lean Techniques
Creating a Future State Map
Using a Map as a basis for Tactical Implementation Planning

34. Summary
Just do it !