•O-ring, bearing, snap ring • Daily schedule
Assembly DIST
C/T = 30 Sec C/O = 30 Min Uptime 75% Batch Size 100
1000 pcs
C/T = 45 Sec C/O = 60 Min Uptime 95% Batch Size 100

The learning objective for this course is not:

To teach Lean Tools to help achieve Future State
Value Stream Mapping
3
What’s in It for Me?

Define
Value stream mapping is a visual tool to help understand the current value stream.

Define
Assign Value Stream Manager

One person to manage the mapping of the total flow Has the capability to make changes across departmental boundaries Leads the creation and prioritization of the implementation plan for getting from present state to future state Monitors implementation and updates implementation plan Driver for results
5000 pcs
C/T = 60 Sec C/O = 5 Min Uptime 95% Batch Size 100
100 pcs
C/T = 50 Sec
C/O = 10 Min Uptime 95% Batch Size 100
200 pcs
15 hours 30 sec 45 sec
83 hours 60 sec
Value Stream Mapping
5
Value Stream Mapping Process Steps

Define
Identify Current State
Step 1: SIPOC Chart Step 2: Top Down Flow Chart Step 3: Determine Product Family

Step 4: Step 5: Step 6: Step 7:

Hale Waihona Puke Draw Process Flow Draw Material Flow Draw Information Flow Process Data Collection


Step 8: Add Process and Lead Time data Step 9: Verify Current State Map
Mat Bin
Forge Machine
Module
Assembly
TPM
Batch
200 pcs
Set-up Reduction
FIFO
Max 100 pcs
Assembly
2/Day
FIFO
Max 200 pcs
DIST
C/T = 30 Sec C/O = 30 Min Uptime 95% Batch Size 100
Define
ASSEMBLY
90/60/30 Day
Customer
Production Control
Daily Order Daily Order
20,000 pcs/mo Module=100
Daily
Mat
1) Set-up reduction 2) Pull Systems 3) TPM
Receiving Warehouse


Value Stream Mapping
7
Current State VSM
6 Month Forecast
SUPPLIER
Define
ASSEMBLY
90/60/30 Day
Customer
MRP
1/Week
Production Control
Daily Order
Weekly Fax
20,000 pcs/mo Module=100
Measure
Value Stream Mapping
SIPOC Top-Down
Analyze
Map Mapping
Value-Stream
Improve
Control
Process Mapping Hierarchy
SIPOC chart
S U P P L I E R I N P U T

Value Stream Mapping
2
Learning Objectives

Define
The learning objectives for this course are:

Be able to create Current State and Future State Value Stream Maps Be able to use customer and business requirements to prioritize improvement opportunities

Identify and Prioritize Improvement Opportunities Determine Future State Implement Improvements to Achieve Future State
6
Value Stream Mapping
Value Stream Manager
2.5 hours 30 sec
10 hours
2 hours 60 sec
4 hours
Production lead time = 18 hours 33 min Processing time = 185 seconds
45 sec
50 sec
9
Value Stream Mapping
9
Define
C/T = 45 Sec
C/O = 10 Min Uptime 95% Batch Size 100
500 pcs
C/T = 60 Sec C/O = 5 Min Uptime 95%
Module Size100
C/T = 50 Sec C/O = 10 Min Uptime 95%
Module Size 100
300 Per Day 400 Min Avail 1 Shift C/T 12 Min
Single Plant
1200 Min Avail
3 Shift C/T 3 Min
Process Steps
Value Stream Mapping
11
Router Steps
Define
Measure
Analyze
Supplier Input Process Output Customer (SIPOC) Map
Step 1
Improve
Control
Step 1: High-Level SIPOC Chart

Define
Supplier Input Process Output Chart (SIPOC)
13
Step 1: The SIPOC Chart
Translate
Define
Customer requirements into output specifications and identify related Key Process Output Variables (KPOVs) Go Upsteam to the Process Steps(s) which most impact the OUTPUT and determine the Key Process Input Variables (KPIVs) Try to use Leading Measure(s) (instead of Lagging Measures – if lagging, then Close/Reduce amount of Lagging)
Define
PROCESS
O U T P U T
C U S T O M E R
Company
Top Down Process Flow
Step 1
4
Mult. Plants
VSM
48
I
Step 2 2
180 Per Day
22
I
Step 3 1
450 Per Day 400 Min Avail 1 Shift C/T 7 Min
Define
Measure
Value Stream Mapping
Analyze
Improve
Control
Agenda

Define
Monday
Kick-Off Introductions Current State Steps 1-4


Tuesday

Current State Steps 5-7
It allows people to easily understand where waste exists in the process. It gives the team a basis for prioritizing improvement efforts.