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7/23/2019 Value-Stream-Mapping.pdf http://slidepdf.com/reader/full/value-stream-mappingpdf 1/58 By : Gaurav Narula Demand Chain Solutions Value Stream Mapping Gaurav Narula
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Page 1: Value-Stream-Mapping.pdf

7/23/2019 Value-Stream-Mapping.pdf

http://slidepdf.com/reader/full/value-stream-mappingpdf 1/58

By : Gaurav Narula

Demand Chain Solutions

Value Stream Mapping

Gaurav Narula

Page 2: Value-Stream-Mapping.pdf

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By : Gaurav Narula

A Value Stream Map is a simple

picture that helps you focus onflow and eliminate the waste

Lean ImplementationWhy do Value Stream Mapping?

 

Finished GoodsAssembly

Layout

Welding

R olling  6 ! "  F or e#a st  Wee " l y $ rde r

6 % & Day

'C ( L

6!" ) ore#ast

Daily

Level Bo%

  DA*  DA+  DA,

C&$ -ime .

C- .

-A/- -ime

, Shi)ts

D- .

S#ra0 .

Stam0ing

1 $vertime

+ Shi)ts

2a% Si3e

4 2aterial 5andlers

C&$ -ime .

C- .

-A/- -ime

, Shi)ts

D- .

S#ra0 & Re!or" .

C&$ -ime .

C- .

-A/- -ime

, Shi)ts

D- .

S#ra0 & Re!or".

Small Lot 4 $0erators

Customer 

0#s& mont hStd 'a#" 7ty

4 Shi)ts

W8' .

W8' . W8' .

Steel Su00lier 

8nv9-ime'ro#9-ime -'#&t . days days days days

days days days

MAP THE FLOS !

3

Eyes for Waste . . .. . . Eyes for Flow 

Page 3: Value-Stream-Mapping.pdf

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By : Gaurav Narula

$b;e#tives

<%0lain =alue Stream 2a00ing

Com0lete a Current State =alueStream 2a0

Com0lete a Future State =alue Stream2a0 !ith 0ro0osed 8m0lementation'lan

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By : Gaurav Narula

Agenda

"ntroduction to Value Stream Mapping

#urrent State Map

$ata #ollection

Acti%ity& Map #urrent State Revie! Current State 2a0

Design Future State

Future State 2a0

Consider /ey 7uestions Summary

A#tivity: Design Future State

Session

1

Session

2

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By : Gaurav Narula

Agenda Session *

"ntroduction to Value Stream Mapping

Current State 2a0

Data Colle#tion

A#tivity: 2a0 Current State

Page 6: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Design Raw Materials

Definition of Value Stream

 Assembly Plants Distribution Customer 

2

Parts Manufacturing

Introduction to Value Stream Mapping

 A Value Stream includes all elements (bot !alue added and

non"!alue added# tat occur to a gi!en product from its

inception troug deli!ery to te customer$

Re%uirements

Page 7: Value-Stream-Mapping.pdf

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By : Gaurav Narula

VALUE STREAM 

PROCESS PROCESS PROCESS 

Introduction to Value Stream Mapping

&ypically we e'amine te !alue stream from raw

materials to finised goods witin a plant$

Definition of Value Stream

It is also possible to map business processes

using Value Stream Mapping .

1

Page 8: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Value Stream Mapping (VSM# is a ands"on process tocreate a grapical representation of te process material

and information flows witin a !alue stream$

Definition of Value Stream Mapping 

 

Finished GoodsAssembly

Layout

Welding

R olling  6 ! "  F or e#a st  Wee" ly $ rde r

6 % & Day

'C ( L6! " )ore#ast

Daily

Level Bo%

  DA*

  DA+

  DA,

C&$ -ime .

C- .

-A/- -ime

, Shi)ts

D- .

S#ra0 .

Stam0ing

1 $vertime

+ Shi)ts

2a% Si3e

4 2aterial 5andlers

C&$ -ime .

C- .

-A/- -ime

, Shi)ts

D- .

S#ra0 & Re!or" .

C&$ -ime .

C- .

-A/- -ime

, Shi)ts

D- .

S#ra0 & Re!or".

Small Lot 4 $0erators

Customer 

0#s& monthStd 'a#" 7ty

4 Shi)ts

W8' .

W8' . W8' .

Steel Su00lier 

8nv9-ime'ro#9-ime

-'#&t . days days days days

days days days

Future State Material, Information and Process Flows

with total Product Cycle Time

Introduction to Value Stream Mapping

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By : Gaurav Narula

Pro!ide te means to see te material processand information flows$

Support te prioriti)ation of continuous

impro!ement acti!ities at te !alue stream Pro!ide te basis for facility layout

Objectives of Value Stream Mapping 

Eliminate Waste

1

Introduction to Value Stream Mapping

 AND...

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By : Gaurav Narula

Map the #urrent State

he !rocess

Analy'e the #urrent State

and

$esign the Future State

Introduction to Value Stream Mapping

-ues9 (Fri9

'C ( L

 Wee "  l y $ rde r2R' 2SS

  W e e  " l y 

 $ r d e r

4 times&day

SteelSu00lier 

Steel

'in

40#s

4 days

orshi)ts

" ""

"Stam0ing

Do!ntime

Changeover-ime.> hr 

+ Shi)ts

-A/-.

  + 'resses

 Cy#le -ime.

Change$ver 

Welding

Layout

S#ra0&Re!or" 

Do!ntime. +1?

@0time

4 $0erators

Cy#le -ime .

Wee"ly Build S#heduleDaily Shi0

S#hedule

6  Wee "  R o lli ng Fo re#as t

 6  W e e "  R  o

 l l i n g F o r e #

 a s t

Finished Goods

$vertime .

4 Shi)ts .

Assembly

D- S#ra0Re!or" 

W8' .

Cy#le -ime .

-A/-.

 Changeover -ime.

Layout

  . *1?

S#ra0

days days days days

days days days

8nventory -ime

'ro#essing -ime-'#&t .

-A/-.

  W8' .

  W8' . W8' .

0#s&month

Std9'a#"7ty9

4 shi)ts

Customer 

 

Finished GoodsAssembly

Layout

Welding

R olling 6 ! "  F ore#ast  Wee "l y $ rde r

6% & Day

'C ( L6! ")ore#ast

Daily

LevelBo%

 DA*

 DA+

 DA,

C&$-ime.

C-.

-A/--ime

, Shi)ts

D-.

S#ra0 .

Stam0ing

1 $vertime

+Shi)ts

2a% Si3e

4 2aterial5andlers

C&$-ime.

C-.

-A/--ime

, Shi)ts

D-.

S#ra0 &Re!or".

C&$-ime.

C-.

-A/--ime

,Shi)ts

D-.

S#ra0 &Re!or".

Small Lot 4 $0erators

Customer 

0#s& month

Std 'a#"7ty

4 Shi)ts

W8'.

W8'. W8'.

SteelSu00lier 

8nv9-ime

'ro#9-ime-'#&t .

days days days days

days days days

#reate an implementation plan and

e(ecute it !

)ST *+$ ,-$ .TH )ST *+$ ,-$ .TH

<stablish -A/- ( Flo! in -an" Assy

Stam0ing Changeover Redu#tion

Redu#e Stam0ing Bu))er 

2ove Assy to 'lant *1

<stablish -A/- ( Flo! in Sender Assy

'ull -o Sender Assy

-raining

)/// *000

Acti%ity

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By : Gaurav Narula

Agenda Session *

8ntrodu#tion to =alue Stream 2a00ing

#urrent State Map

Data Colle#tion

A#tivity: 2a0 Current State

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By : Gaurav Narula

Current State Maphe Steps

Select a Product *amily

*orm a &eam

+nderstand Customer Demand

Map te Process *low

Map te Material *low

Map te Information *low

Calculate &otal Product Cycle &ime

Detail ,ff"Line Acti!ities

Step -.

Step /.

Step 0.

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

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By : Gaurav Narula

Define !alue stream (product family#

 6 Identify !alue stream from te customer end

 6 Product sould pass troug similar processesand common e%uipment

 6 Door"to"door in scope (witin plant walls#

List part numbers

Current State MapStep "# Select a Value Stream $!roduct %amily&

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By : Gaurav Narula

Select a cross"functional team

Select team members

wo are familiar wit

te product

7nsure tat team

members are trained in te

use of VSM

Designate a campion (typically a line manager#

Current StateStep '# %orm a eam

Cross *unctional

&eam

Manufacturing

PC 8 LMaintenance

Leadersip

Product7ngineering

Industrial

7ngineeringSensei

TH"S "S #-"T"#AL

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By : Gaurav Narula

Plan for 7!ery Part

Production Control

(montly9wee:ly forecasts#

Production istory (day"to"day mont"to"mont

!ariation#

Sales (product canges new business etc$#

Current State MapStep (# )nderstand *ustomer Demand 

Customer 

Demand&month:

'art A .

'art B .

'art C .

4 o) shi)ts .

1

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Customer 

Demand&month:

'art A .

'art B .

'art C .

4 o) shi)ts .

Current State Map

8nventory

'art A .

'art B .

'art C .

4 o) shi)ts .

Shi00ingAssemblyWeldingStam0ing

-a"t .

C9-9 .

D9-9 .

F-7 . 1?

C&$ -ime .

Lot Si3e .

4 o) Shi)ts

W8' .

-a"t .

C9-9 .

D9-9 . +1?

F-7 .

C&$ -ime .

Lot Si3e .

4 o) Shi)ts

W8' .

-a"t .

C9-9 .

D9-9 .

F-7 .

C&$ -ime . > hrs9

Lot Si3e .

4 o) Shi)ts

W8' .

Changeover Do!ntime F-7

By : Gaurav Narula

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Step +# Map the Material %lo, 

Customer 

Demand&month:

'art A .

'art B .

'art C .

4 o) shi)ts .

8nventory

'art A .

'art B .

'art C .

4 o) shi)ts .

Shi00ingAssemblyWeldingStam0ing

-a"t .

C9-9 .

D9-9 .

F-7 . 1?

C&$ -ime .

Lot Si3e .

4 o) Shi)ts

W8' .

-a"t .

C9-9 .

D9-9 . +1?

F-7 .

C&$ -ime .Lot Si3e .

4 o) Shi)ts

W8' .

-a"t .

C9-9 .

D9-9 .

F-7 .

C&$ -ime . > hrs9

Lot Si3e .

4 o) Shi)ts

W8' .

Changeover  Do!ntime F-7

Current State Map

+ %&

day

8

+ %&

!ee" 

Su00lier 

*+11 0#s

8*11 0#s

8E11 0#s

811 0#s

By : Gaurav Narula

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Customer 

Demand&month:'art A . 1 0#s9

'art B . 611 0#s9

'art C . *61 0#s94 o) shi)ts .

8nventory

'art A . 1 0#s

'art B . 611 0#s

'art C . *61 0#s

4 o) shi)ts .

Shi00ingAssemblyWeldingStam0ing

-a"t .

C9-9 .

D9-9 .

F-7 . 1?

C&$ -ime .

Lot Si3e .

4 o) Shi)ts

W8' . 1 0#s9

-a"t .

C9-9 .

D9-9 . +1?

F-7 .

C&$ -ime .

Lot Si3e .

4 o) Shi)ts

W8' . 61 0#s9

-a"t .

C9-9 .

D9-9 .

F-7 .

C&$ -ime . > hrs9

Lot Si3e .

4 o) Shi)ts

W8' . + 0#s9

Changeover  Do!ntime F-7

8 8 88

+ %&

day

+ %&

!ee" 

Su00lier 

*+11 0#s *11 0#s E11 0#s 11 0#s

'C ( L

Wee"ly Build S#hedule

Daily Shi0 S#hedule

6 !ee" rolling )ore#ast

6 !ee" rolling )ore#astWee"ly $rder 

Wee"ly $rder 

Current State MapStep -# Map the Information %lo, 

By : Gaurav Narula

Page 19: Value-Stream-Mapping.pdf

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Step # *alculate otal !roduct *ycle ime

Customer 

Demand&month:

'art A . 1 0#s9

'art B . 611 0#s9

'art C . *61 0#s9

4 o) shi)ts .

8nventory

'art A . 1 0#s

'art B . 611 0#s

'art C . *61 0#s

4 o) shi)ts .

Shi00ingAssemblyWeldingStam0ing

-a"t .

C9-9 .

D9-9 .

F-7 . 1?

C&$ -ime .

Lot Si3e .

4 o) Shi)ts

W8' . 1 0#s9

-a"t .

C9-9 .

D9-9 . +1?

F-7 .

C&$ -ime .

Lot Si3e .

4 o) Shi)ts

W8' . 61 0#s9

-a"t .

C9-9 .

D9-9 .

F-7 .

C&$ -ime . > hrs9

Lot Si3e .

4 o) Shi)ts

W8' . + 0#s9

Changeover Do!ntime F-7

8 8 88

+ %&

day

+ %&

!ee" 

Su00lier 

*+11 0#s *11 0#s

E11 0#s

11 0#s

'C ( L

Wee"ly Build S#hedule

Daily Shi0 S#hedule

6 !ee" rolling )ore#ast

6 !ee" rolling )ore#astWee"ly $rder 

Wee"ly $rder 

9+ days 9* days9> days 9 days

*91 days9*E days91+ days911E days-'#&t . +9 days

By : Gaurav Narula

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By : Gaurav Narula

Step /# Detail Off01ine 2ctivitiesCurrent State Map

Sow on te map using general icons

Detail on anoter seet using eiter reference

VSM and9or process flow"carting

8Dies

Die Room

Re#eivingDie Room

Shi00ingRemove )rom

S#hedule

BoardH

Die Ben#h

8Dies

+ shi)ts*+ shi)ts

S#hedule Board

Fore#astH

For" -ru#" 

'ress Room

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By : Gaurav Narula

FIFO

Su0ermar"et

Signal/anban

Withdra!al

/anban

'rodu#tion

/anbanLeveling

'hysi#al

'ull

/anban

arriving

in bat#hes

/anban'ath

/anban'ost

First8n

First$ut

Flo!

MAX 50 PCS

'ro#ess

/ai3en

Current State Map 2dditional Mapping Icons

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By : Gaurav Narula

It is not necessary tat attribute data beprecise$ It is necessary tat te information at least be

directionally correct$

;nowing tat uptime is 5/$4< !s$ 5/<

is normally not necessary$ An assumption of 5=< owe!er

wen reality is 32< can be

detrimental in tat it may substantially

misdirect te future state de!elopment

and te prioriti)ation of impro!ement

acti!ities$1

Data Collection

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By : Gaurav Narula

Agenda Session *

8ntrodu#tion to =alue Stream 2a00ing

Current State 2a0

$ata #ollection

A#tivity: 2a0 Current State

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By : Gaurav Narula

 2ttribute Data to *ollect 

>ow ,perations are

sceduled

Sipping9Recei!ingscedules

Pac: si)es at eac

process

Demand rates byprocess (&a:t &ime#

?or:ing ours and

brea:s

In!entory Points(location 8 si)e#

?or:"in"processin!entory

,!ertime per wee:

Process cycle times @umber of product

!ariations at eac step

atc (lot# si)es

Cangeo!er times

Cangeo!er 

 fre%uencies

Scrap Rewor:

Downtime

Data Collection

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By : Gaurav Narula

Tailor thedata !o" for

your #lant$s

needs%The data!o" should

!e o#en

ended to

allow foradditional

attri!utes%

  D a  t a   A o  '

Data 3o4 Data Collection

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By : Gaurav Narula

S#ra0

2anu)a#turing

'ro#ess/ai3en

Lightning

Burst

$utside

Sour#e&

Customer 

Data Bo%

8nventory

8

o o o-ru#" 

Shi0ment

Finished

Goods to Customer 

'ush Arro!

Su0ermar"et

Bu))er or 

Sa)ety Sto#" 

2anual

8n)ormation Flo!

<le#troni#

8n)ormation Flo!

'rodu#tion/anban

Withdra!al /anban

Signal /anban

/anban 'ost

oolsIntroduction to Value Stream Mapping

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By : Gaurav Narula1

What is a5t ime?

Data Collection

Takt Time is the rate at which production should runto meet customer demand 

-he idea is to synchroni'e the 0a#e o)

 0rodu#tion to the 0a#e o) sales9

27,000 sec460 pieces

= 59 sec

59 sec.

59 sec.

59 sec.

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By : Gaurav Narula

  1% &etermine Total Customer 'e(uirements for the  affected #rocess$

2%  &etermine the Scheduled 'untime )S%'%* for the

  affected #rocess+

  Sceduled Runtime B (7ffecti!e Minutes# " (Planned Downtime#

  7ffecti!e Minutes B (minutes per sift# " (appro!ed brea:s#

  Planned Downtime is te amount of time an operation is down

  for sceduled reasons$ 

3%  Calculate Tat Time+

Scheduled 'untimeTat Time -

Total Customer 'e(uirements

3

6o, to *alculate a5t ime?

Data Collection

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By : Gaurav Narula

Identify Opportunities for Improvement 

Data Collection

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By : Gaurav Narula

Agenda Session *

8ntrodu#tion to =alue Stream 2a00ing

Current State 2a0

Data Colle#tion

Acti%ity& Map #urrent State

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By : Gaurav Narula

A#tivity: 2a0 the Current State

I #omplete draft  of current state %aluestream map1

I -e%iew draft and identify openissues1

I -esol%e open issues1 #omplete

current state %alue stream map1

I Session *  -e%iew current state %alue streammap1

Com#lete .y Tas/##ro"imate

Total Time+

 

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By : Gaurav Narula

Session +

Agenda Revie! #urrent state

$ver vie! o) develo0ing )uture state

Develo0 )uture state Develo0 a#tion 0lans to get to )uture state

Assign o!ners timing and )reJuen#y o) revie! )or a#tion

items

Re0ort to leadershi0

Su00ort

Learning

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By : Gaurav Narula

Agenda Session +-e%iew #urrent State Map

$esign Future State 2 Purpose

Future State 2a0

Consider /ey 7uestions

Summary

A#tivity: Design Future State

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By : Gaurav Narula

Agenda Session +Revie! Current State 2a0

I Design Future State 'ur0ose

I Future State Map

I Consider /ey 7uestions

I Summary

I A#tivity: Design Future State

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By : Gaurav Narula

Define ow te plant will

operate in te future

Ser!e as te blueprint

for implementation

Design *uture State " Purpose!urpose

ithout it3 the #urrent State Map is

nothing more than wallpaper !

1

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By : Gaurav Narula

*uture State Map

Step -.Step /.

Step 0.

Step 1.

Step 2.

Step 3.

Step 4.

he Steps

Validate Customer DemandDraw te *uture State Process *low

Map te *uture State Material *low

Map te *uture State Information *low

Calculate &otal Product Cycle &ime

Detail ,ff"Line Acti!ities

0utline a Plan

2

Page 37: Value-Stream-Mapping.pdf

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By : Gaurav Narula

,riginal Condition

Step# Outline a !lan

*uture Condition

8n;:2olding

+Sender AssKy

+

2SS

AssKy'lants

Stam0ing

*1-an" AssKy

>

'er)orm to -A/- ( 'it#h9

'rodu#e to $rder 

Load Leveling and 'ull

one 2aintenan#e ( Fast Res0onse

Labels

LevelABABA9 9 9

Staging by -ru#" 

#ard by#ard

'it#h . *> @nitsH

)ST *+$ ,-$ .TH )ST *+$ ,-$ .TH

<stablish -A/- ( Flo! in -an" Assy

Stam0ing Changeover Redu#tion

Redu#e Stam0ing Bu))er 

2ove Assy to 'lant *1

<stablish -A/- ( Flo! in Sender Assy

'ull -o Sender Assy

-raining

)/// *000Acti%ity

 

8n;:2olding

+

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Change$ver 

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 No Flo!

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@0time

"tem #urrent Target

-otal 0rodu#t #y#le time

'arts & 'erson 5our 

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8nventory daysH

$vertime

@0time

MET-"#S

*uture State Map

Page 38: Value-Stream-Mapping.pdf

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By : Gaurav Narula

*uture State Maphe Steps

4$o "t5"mplement 2 "mplement 2 "mplement

Action 2 Action 2 Action 2 Action 2 Action

4#hec6 "t 2 Follow up5

Page 39: Value-Stream-Mapping.pdf

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By : Gaurav Narula

 A simple way to

approach the FutureState Map is to begin

by modifying the

Current State Map.

*uture State Maphe Steps

Page 40: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Agenda Session +Revie! Current State 2a0

Design Future State 'ur0ose

Future State 2a0

#onsider 7ey 8uestions

Summary

A#tivity: Design Future State

Page 41: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Where will you need to use su#ermaret #ull systems to

control #roduction of u#stream #rocesses

What is Tat Time

Will you !uild to a finished oods su#ermaret or directly to shi##in

Where can you use continuous flow #rocessin

/t what sinle #oint in the #roduction chain will you schedule

#roduction )Ty#ically, this will !e the final #rocess%*

ow will you le4el the #roduction mi" at the #acemaer #rocess

What increment of wor will you consistently release

and tae away at the #acemaer #rocess

What #rocess im#ro4ements will !e necessary at the 4alue

stream to flow as your future state desin s#ecifies

Consider ;ey uestions

Page 42: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Will you build to a finished goods supermar5etor directly to shipping?

Every effort should

be madeto minimize thesevariations. Thesevariations are drivenby one of the sevenforms

of waste and shouldbe eliminated.Eliminate Waste

Consider ;ey uestions

The Wall

of Protection+

,ur Manufacturing Plant &e Customer  

Finished 5oods Su#ermaret

Protects your customer from significant

process !ariation$

Protects your manufacturing operation

from significant demand !ariation$

Page 43: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Where can you use continuous flo, processing?

Consider ;ey uestions

Bat#h 'ro#ess

Process

4A5

Process

495

Process

4#5

I I<la0sed -ime:

61 2inutes

3

Process

4A5

Process

495

Process

4#5

Continuous Flo! $ne'ie#e Flo!H

<la0sed -ime:

1* 2inute

$3atch !rocess vs. *ontinuous %lo,&

Page 44: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Where can you use continuous flo, processing?

Consider ;ey uestions

Bat#h 'ro#ess

Continuous Flo! $ne'ie#e Flo!H

Process

4A5

Process

495

Process

4#5

Process

4A5

Process

495

Process

4#5

I I

<la0sed -ime:

61 2inutes

<la0sed -ime:

1* 2inute

$3atch !rocess vs. *ontinuous %lo,&

Page 45: Value-Stream-Mapping.pdf

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By : Gaurav Narula

&is %uestion is as:ing were you will re%uiresupermar:ets or were you will a!e coupled

processes$

7!aluate te following factors wen consideringtis %uestion.

Cycle &ime Compatibility

7%uipment +ptime9Downtime (remember tat

coupling can multiply te effects of downtime#

7%uipment In!estment

*le'ibility

Where can you use continuous flo, processing?

2

Consider ;ey uestions

Page 46: Value-Stream-Mapping.pdf

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By : Gaurav Narula

&ypically a pull system is needed were!er continuousflow stops$

&e only e'ception would be to use a simple *I*, system$

*I*, may wor: in situations were only in!entory%uantity needs to be controlled (not se%uencing batc

si)ing etc$#$

Visual %uantity control is needed " witout pysically

counting parts and sceduling macine operation$

Where ,ill you need to use supermar5et pull  systems to control production of upstream processes?

2

Consider ;ey uestions

FIF0

Page 47: Value-Stream-Mapping.pdf

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By : Gaurav Narula

 2t ,hat single point in the production chain ,ill you

schedule production?

Consider ;ey uestions

FIF0

 AssemblyMolding

PC8L

o'o'

Pacemaer Process

+sually you will scedule

production at te final process$

7'ceptions to tis migt be were

your final process is suppliedtroug *I*,$

1

Page 48: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Consideration must be gi!en to le!el bot te mi' and o!erall %uantity ofproduct sceduled for production$

Le!eling of te production scedule is a fundamental re%uirement for te

efficient management of operations

6o, ,ill you level the production mi4 at the pacema5er process?

2

-ime

Wor"

load

?itout Le!eling

Wor"

load

-ime

?it Le!eling

Consider ;ey uestions

Page 49: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Le!eling of te o!erall production %uantity must be supported by tele!eling of te product mi'$

6o, ,ill you level the production mi4 at the pacema5er process?$*ontinued&

9 Fri9

Part D

Part C

Part A 8

Part D

Part D

2on9 -ue9 Wed9 -hu

&raditional Sceduling

Daily Production

Mon 104= Part D

&ue 104= Part D

?ed 104= Part D

&u 104= Part C

*ri 0/44 -=/ A

Le!el Sceduling

2on9 -ue9 Wed9 -hu9 Fri9

Part APart

Part CPart D

Part APart

Part CPart DPart A

Part Part C

Part DPart A

Part Part C

Part DPart APart

Part CPart D

Daily Production

Part A /-5Part 322

Part C 541

Part D /3//

2

Consider ;ey uestions

Page 50: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Le!eling of te product mi' must be

supported by small lot production$

Small lot production must be supported by%uic: set"up$

6o, ,ill you level the production mi4 at the pacema5er process?$*ontinued&

Consider ;ey uestions

Page 51: Value-Stream-Mapping.pdf

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By : Gaurav Narula

 An effecti!e way

of communicating

te le!el sceduleto manufacturing

operations can be

troug te use of

a load le!elingbo'$

6o, ,ill you level the production mi4 at the pacema5er process?$*ontinued&

Consider ;ey uestions

Page 52: Value-Stream-Mapping.pdf

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By : Gaurav Narula

'art

<

'art

D

'art

C

'art

B

'art

A

2on -ues Wed -hurs Fri Sat   Sun

Build

$rder 

Macro2Le%eling

What increment of ,or5 ,ill you consistentlyrelease and ta5e a,ay at the pacema5er process?

Consider ;ey uestions

Page 53: Value-Stream-Mapping.pdf

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By : Gaurav Narula

'artC

'art

B

'art

A

E:11 E:*1 E:+1 E:,1 E:>1 E:D1 :11 :*1 :+1

 C  a r  d  G  '  a r  t  A H  

 C  a r  d  G  '  a r  t  A H  

 C  a r  d  G  '  a r  t  A H  

 C  a r  d  G  '  a r  t  B H  

 C  a r  d  G  '  a r  t  B H  

 C  a r  d  G  '  a r  t  B H  

 C  a r  d  G  '  a r  t  B H  

 C  a r  d  G  '  a r  t   C  H  

 C  a 

r  d  G  '  a r  t   C  H  

$ne #olumn 0er 0it#h

G<Juals *1 minutesH

/anban

G0ull #ardH

 $n e r  o ! 0 e r 

 0 a r  t  n um b  e r 

Std 'a#" . *1 0#s

-a"t -ime . * min9

Build $rder 

SeJuen#ed and -imed

Micro2Le%eling

What increment of ,or5 ,ill you consistentlyrelease and ta5e a,ay at the pacema5er process?

$*ontinued&

Consider ;ey uestions

Page 54: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Agenda Session +Revie! Current State 2a0

Design Future State 'ur0ose

Future State 2a0

Consider /ey 7uestions

Summary

A#tivity: Design Future State

C id ; ti

Page 55: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Data is analy)ed todetermine waste

(inibitors to flow#$

Plans are de!eloped toreduce or eliminate

waste$

What process improvement are necessary for the value stream to flo, as your future state design specifies?

&is step is :ey to any successful

!alue stream impro!ement

acti!ities$

Consider ;ey uestions

his is the step ,here

,e can most impact

the bottom line.

S

Page 56: Value-Stream-Mapping.pdf

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By : Gaurav Narula

<%0lain =alue Stream 2a00ing

Com0lete a Current State =alue Stream 2a0

Com0lete a Future State =alue Stream 2a0

!ith 0ro0osed 8m0lementation 'lan

SummaryObjectives 7evie, 

Page 57: Value-Stream-Mapping.pdf

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By : Gaurav Narula

Agenda Session +Revie! Current State 2a0

Design Future State 'ur0ose

Future State 2a0

Consider /ey 7uestions

Summary

Acti%ity& $esign Future State

Page 58: Value-Stream-Mapping.pdf

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B G N l

A#tivity: Design Future State

&as:

:sing the current state map for your selected %alue

stream3 design your future state1Outline a plan1

-e%iew future state design and plan1

/##ro"imate

Total Time+

 


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