Total Value Stream
Supplier
Process C
Process B
Process A
Customer
Internal Plant
2
Value Steam Mapping
What is Value Stream Mapping?
Value Stream Mapping is a powerful technique that allows us to create a “BIG PICTURE” visual representation of: – All the steps in the process, working back from customer demand to raw material – The flow of both material and information and the effect they have on each other – The distinction between value-added and non-valueadded activity (WASTE) – The effect all of the above have on meeting the customer’s requirements
15
Value Steam Mapping
Small Group Activity
• Identify who in your organization will fill these critical roles to support lean implementation – Executive Champion – Implementation Leader – Operations Manager – Technical Support – Other Key Roles? • Briefly describe the role each person will have in supporting lean • What can you do to get these people to successfully support your efforts
3
Value Steam Mapping
The 8 Wastes
Scrap/Rework
Over-production
Inventory
Motion
Processing
Transportation
Under-utilized People Waiting (manpower, material, machine)
12
Value Steam Mapping
Exercise Worksheet
MANUFACTURING WASTES IDENTIFICATION SHEET
Dept: _______________
Transportation Under-utilized People Scrap/Rework Over (Under) Production Processing
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Value Steam Mapping
#8 Under-utilized People
Definition:
– Skills untapped, Ideas not implemented and improvements not realized
Goal:
– Tap into the energies and unused improvement ideas from the workforce
1. Understand business goals and customer objectives 2. Select champion and value stream leaders based on proven criteria for success 3. Define product families based on common processes and equipment
Value Stream Mapping
Value Steam Mapping
The Value Stream - a definition
“All of the steps required to bring a product or service from raw state through to the customer”
9
Value Steam Mapping
#6 Transportation
Definition:
– Moving parts to unnecessary distances from one:
– Put operations in order; minimize or eliminate the travel distance between them
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Value Steam Mapping
Leadership and Champions
Observations
Lean Aerospace Initiative
– A common factor in all observed successful lean implementations is one or more empowered Champions. – Champions are usually high-level leaders who take on a pro-active role shaping and supporting the lean initiatives, and ensuring that system barriers are identified and addressed. – To start your lean journey, you need a leader or set of leaders to: • Develop a strategic direction • Agree to and communicate the strategic direction • Make available the needed resources • Provide continued, visible support – Without the support of a champion, you should not attempt to implement lean practices and principles -- it is a recipe for disaster
Goal:
Same as Definition
???
sitting
searching
turning around
walking
climbing
choosing
bending lying down over
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Value Steam Mapping
#5 Processing (Over & Under)
– 100% First Time Through Quality
5
Value Steam Mapping
#2 Over-production (Under)
Definition:
– Producing more than is necessary, often causing WIP (Work In Process); working on parts ahead of schedule while delinquent parts wait
– Operations that can potentially be dedicated to the product family – Operations that are neither monuments nor batch cycles – Downstream processes most visible to the customer
Value Stream Analysis Process
Value Stream Mapping 1.0 Select Champion and Initial Product Family 2.0 Gather, Map, and Analyze Selected Value Stream Data 3.0 Design Future State 4.0 Implementation Planning and Execution
• Executive Champion • Implementation Leader • Operational Mgr
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Value Steam Mapping
Define Product Families
• Analyze Product-Volume Chart to separate high runners from low runners • Analyze Product-Process Matrix to identify similar processing steps and common equipment • Analyze Routings to identify common sequences focusing on:
Goal:
– Produce to Target Cycle Time then eventually produce all operations to Takt Time in the Future State
6
Value Steam Mapping
# 3 Inventory
Definition: material or parts that are stored for future use or shipment