The downstream customer of any internal upstream process.
Your company as the customer of external suppliers.
6
Flow
• Ideal flow = 1 piece at a time • Rate determined by customer demand - Takt time • Work balanced for each person or machine • Travel distance for materials & people minimized • Standard Work utilized
From “Lean Lexicon”
3
Order Fulfillment Value Stream
Sales Order Receipt
RM Order & Receipt
Manufacturing
Packaging
Distribution
Delivery/ Service
Ideally, we’d want the materials, information and cash to flow smoothly (without interruption) and as quickly as possible through this stream.
Manual Information Flow
Electronic Information Flow
Weekly Schedule
Schedule
XOXO
Load Leveling Box
Withdrawal Kanban
Production Kanban
Signal Kanban
Kanban Post
K anbanPath K anbanP ost
W ith d ra w a l K a n b a n
M a te r ia lF lo w Ic o n s
C /T = C /O =
K a n b a n A r r i v i n g i n B a t c h e sL o t-M a k in g B o a rd
4
Lean Elements
Value is Determined by$Βιβλιοθήκη $Customer$
1 Piece Flow
Strive for
5
Value
• “What is the
willing to Pay for?”
• 3 Types of Customers:
The external end-user or paying customer
20
Value Stream Mapping Icons
Process Icons
Assembly
Manufacturing Process
Truck Shipment
XYZ Corp.
Outside Sources
PUSH Arrow
C/T = 45 sec C/O = 30 min
3 Shifts 2% Scrap
• This will enable us to prioritize our efforts and focus on the high potential events first.
9
8 Wastes
• Overproduction • Inventory • Waiting • Transporting • Unnecessary processing • Unnecessary motion • Defects • Under utilization of people
7
Phases of Lean Journey
• Phase 1-Identify/Map Value Streams • Phase 2-Prioritize opportunities • Phase 3-Utilize Lean tools to eliminate waste • Phase 4-Control the flow • Phase 5-Lean metrics • Phase 6-Re-evaluate Value Streams and
• Who are the “real” experts ? and what do they know?
18
Purpose of Value Stream Mapping
The purpose of the value stream map is to look at the big picture and to develop a “future-
Mistake-proof to prevent defects
Never Pass defects Standard Work
17
Waste of Underutilizing People
• The eighth waste is not fully utilizing the time and talents of people.
begin again
8
It All starts with Waste Identification
• Identify all forms of Waste throughout our entire Value Stream before:
Reducing the waste or Eliminating the waste
Reducing all other wastes reduces the waste of inventory
12
Waiting
• Waiting for upstream processes due to poor layout, unbalanced work load or equipment downtime.
• 1 Cross-functional Team completes the map • Start at the customer end • Walk the actual pathways of both
material and information flow. • Draw by hand in pencil.
Data Box
I
300 Pieces 1 Day
Inventory
Finished Goods to Customer
max. 20 Pieces
FIFO
First-In-First-Out Sequence Flow
21
Value Stream Mapping Icons
Information Flow Icons
16
Defects (Correction)
• Making defective product is pure (muda) waste. • Focus on preventing defects • Not finding and repairing defects
• Ways to Overcome:
• Ways to Overcome:
Synchronize work flow Balance uneven loads
by flexible workers and equipment Implement preventive maintenance to eliminate machine down-time
layouts and visibility
11
Inventory
• Excess inventory requires handling, space, $$, people, and paperwork.
• Ways to Overcome: Synchronize work flow to reduce accumulation Shorten setup time Reduce lead time Cellular layouts Zero Quality Defects
13
Transportation
• Transportation adds No value to the product. Rather than improve the transportation:
• Reduce it
• Eliminate it.
• Ways to Overcome:
Establish layout and locations which reduces or eliminates transportation
LeanManufacturing ValueStreamMapping
1
What is Lean?
Lean is a
that focuses on:
Creating value for the Customer
Eliminating Waste
Continuous incremental improvement
10
Over-Production
• Producing more than what the customer really wants.
• Ways to Overcome:
Reduce setup times Synchronize time and
amount of processes Create compact
Sequenced-Pull Ball
22
G eneral Icons
S uperm arket