May 1, 2023 www.leanteamsusa.com

Robert BairdPresident

+1 215 353 0696

The 2nd Component Process Design and Visual Value Streams

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Process Design CriteriaCustomer Requirements

CapabilityDemand (Current and Future)

Lead Time

Layout Flow

Cellular design, Product design, or Process design

People Required skills

Number

Support departments

Equipment Automation

DFOEE – Design For Overall Equipment Effectiveness

Support (tables, measurement, IT, security, material handling)

Facility Location

Energy

Structure

Health Safety Environment

Ergonomics, Equipment Safety, Prevention

Hazardous materials

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Process Design Tools

• Computer Aided Design (CAD)• Flowchart • Value Stream Mapping (VSM)• Supplier Input Process Output Customer (SIPOC)• Spaghetti Map• Process statistical software

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Process Design Steps

1. Business need statement2. Establish process design team3. Outline of customer demand and requirement4. Facility review5. Layout design6. Equipment requirements7. People requirements8. Health, Safety, and Environment requirements

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Process SIPOCRequirement

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Step1

Step 2

Step 3

Step 4

0.00

4.00

8.00

12.00

16.00 Task Cycle Time Required Takt Time = 14.98 Sec

Thickness10.5 mm

Color3.5 Delta E

Yield99.05%

Yield99.75%

X-Y Position

Pressure

Units Out5,300/day

Thickness

Heat

Yield99.75%

Units Out5,300/day

Units Out5,300/day

Yield99.995%

WIP1800 Units

WIP1700 Units

WIP1700 Units

Heat Height

ViscosityPressure

3 SIGMA 3 SIGMA4 SIGMA

4 SIGMA

Output

Processes Step1 Step 2 Step 3 Step 4 SystemScheduled Time (seconds) 79,207 79,207 79,207 79,207 Throughput (Units/hour) 300 280 342 400 Inventory Time (Hour) 6 6 5 4 Process Lead Time (Hour) 22Process Yield 99.50%Process Throughput (Units/hour) 280Mth. Sales forecast (Units) 121,600Days in month 23

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DesignVisual Management

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Visual Management RulesALL MUST BE SATISFIED

• 80:20 Manual: Automated data collection Simple and Affordable

• Real time measures• Must provide value

Value Stream Workers Leadership team

• Must inspire conversation in the Gemba• 80:20 Input measures: Output measures• Preventative measures (Inputs)

Quality Capability Safety

• Provides results of intended design (Outputs)• Clear indication of continuous improvement and the HOW

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Contact Us • Lean Teams USA Lean Consulting

• View My Profile on LinkedIn

• Lean Teams USA +1 215 353 0696• Link to 3rd Component

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