Date post: | 13-Feb-2018 |
Category: |
Documents |
Upload: | musa-guersoy |
View: | 216 times |
Download: | 0 times |
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 2/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 3/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 4/58
By : Gaurav Narula
Agenda
"ntroduction to Value Stream Mapping
#urrent State Map
$ata #ollection
Acti%ity& Map #urrent State Revie! Current State 2a0
Design Future State
Future State 2a0
Consider /ey 7uestions Summary
A#tivity: Design Future State
Session
1
Session
2
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 5/58
By : Gaurav Narula
Agenda Session *
"ntroduction to Value Stream Mapping
Current State 2a0
Data Colle#tion
A#tivity: 2a0 Current State
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 6/58
By : Gaurav Narula
Design Raw Materials
Definition of Value Stream
Assembly Plants Distribution Customer
2
Parts Manufacturing
Introduction to Value Stream Mapping
A Value Stream includes all elements (bot !alue added and
non"!alue added# tat occur to a gi!en product from its
inception troug deli!ery to te customer$
Re%uirements
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 7/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 8/58
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 $0erators
Customer
0#s& monthStd 'a#" 7ty
4 Shi)ts
W8' .
W8' . W8' .
Steel Su00lier
8nv9-ime'ro#9-ime
-'#&t . days days days days
days days days
Future State Material, Information and Process Flows
with total Product Cycle Time
Introduction to Value Stream Mapping
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 9/58
By : Gaurav Narula
Pro!ide te means to see te material processand information flows$
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...
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 10/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 11/58
By : Gaurav Narula
Agenda Session *
8ntrodu#tion to =alue Stream 2a00ing
#urrent State Map
Data Colle#tion
A#tivity: 2a0 Current State
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 12/58
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.
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 13/58
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 $!roduct %amily&
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 14/58
By : Gaurav Narula
Select a cross"functional team
Select team members
wo are familiar wit
te product
7nsure tat team
members are trained in te
use of VSM
Designate a campion (typically a line manager#
Current StateStep '# %orm a eam
Cross *unctional
&eam
Manufacturing
PC 8 LMaintenance
Leadersip
Product7ngineering
Industrial
7ngineeringSensei
TH"S "S #-"T"#AL
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 15/58
By : Gaurav Narula
Plan for 7!ery Part
Production Control
(montly9wee:ly forecasts#
Production istory (day"to"day mont"to"mont
!ariation#
Sales (product canges new business etc$#
Current State MapStep (# )nderstand *ustomer Demand
Customer
Demand&month:
'art A .
'art B .
'art C .
4 o) shi)ts .
1
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 16/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 17/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 18/58
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 $rder
Current State MapStep -# Map the Information %lo,
By : Gaurav Narula
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 19/58
Step # *alculate otal !roduct *ycle ime
Customer
Demand&month:
'art A . 1 0#s9
'art B . 611 0#s9
'art C . *61 0#s9
4 o) shi)ts .
8nventory
'art A . 1 0#s
'art B . 611 0#s
'art C . *61 0#s
4 o) shi)ts .
Shi00ingAssemblyWeldingStam0ing
-a"t .
C9-9 .
D9-9 .
F-7 . 1?
C&$ -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 $rder
9+ days 9* days9> days 9 days
*91 days9*E days91+ days911E days-'#&t . +9 days
By : Gaurav Narula
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 20/58
By : Gaurav Narula
Step /# Detail Off01ine 2ctivitiesCurrent State Map
Sow on te map using general icons
Detail on anoter seet using eiter reference
VSM and9or process flow"carting
8Dies
Die Room
Re#eivingDie Room
Shi00ingRemove )rom
S#hedule
BoardH
Die Ben#h
8Dies
+ shi)ts*+ shi)ts
S#hedule Board
Fore#astH
For" -ru#"
'ress Room
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 21/58
By : Gaurav Narula
FIFO
Su0ermar"et
Signal/anban
Withdra!al
/anban
'rodu#tion
/anbanLeveling
'hysi#al
'ull
/anban
arriving
in bat#hes
/anban'ath
/anban'ost
First8n
First$ut
Flo!
MAX 50 PCS
'ro#ess
/ai3en
Current State Map 2dditional Mapping Icons
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 22/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 23/58
By : Gaurav Narula
Agenda Session *
8ntrodu#tion to =alue Stream 2a00ing
Current State 2a0
$ata #ollection
A#tivity: 2a0 Current State
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 24/58
By : Gaurav Narula
2ttribute Data to *ollect
>ow ,perations are
sceduled
Sipping9Recei!ingscedules
Pac: si)es at eac
process
Demand rates byprocess (&a:t &ime#
?or:ing ours and
brea:s
In!entory Points(location 8 si)e#
?or:"in"processin!entory
,!ertime per wee:
Process cycle times @umber of product
!ariations at eac step
atc (lot# si)es
Cangeo!er times
Cangeo!er
fre%uencies
Scrap Rewor:
Downtime
Data Collection
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 25/58
By : Gaurav Narula
Tailor thedata !o" for
your #lant$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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 26/58
By : Gaurav Narula
S#ra0
2anu)a#turing
'ro#ess/ai3en
Lightning
Burst
$utside
Sour#e&
Customer
Data Bo%
8nventory
8
o o o-ru#"
Shi0ment
Finished
Goods to Customer
'ush Arro!
Su0ermar"et
Bu))er or
Sa)ety Sto#"
2anual
8n)ormation Flo!
<le#troni#
8n)ormation Flo!
'rodu#tion/anban
Withdra!al /anban
Signal /anban
/anban 'ost
oolsIntroduction to Value Stream Mapping
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 27/58
By : Gaurav Narula1
What is a5t ime?
Data Collection
Takt Time is the rate at which production should runto meet customer demand
-he idea is to synchroni'e the 0a#e o)
0rodu#tion to the 0a#e o) sales9
27,000 sec460 pieces
= 59 sec
59 sec.
59 sec.
59 sec.
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 28/58
By : Gaurav Narula
1% &etermine Total Customer 'e(uirements for the affected #rocess$
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 29/58
By : Gaurav Narula
Identify Opportunities for Improvement
Data Collection
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 30/58
By : Gaurav Narula
Agenda Session *
8ntrodu#tion to =alue Stream 2a00ing
Current State 2a0
Data Colle#tion
Acti%ity& Map #urrent State
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 31/58
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+
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 32/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 33/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 34/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 35/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 36/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 37/58
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
+
Sender AssKy
+
2SS
-an" AssKyStam0ing
Fuel 'um0AssKy
"
"
"
"
"
"
AssKy'lants
+
*+
*1 >
Cy#le-ime Driven9 Bat#hes9
Change$ver
Change$ver
No Flo!
Attendan#e
No Flo!
@0time
"tem #urrent Target
-otal 0rodu#t #y#le time
'arts & 'erson 5our
Delivery 'er)orman#e
8nventory daysH
$vertime
@0time
MET-"#S
*uture State Map
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 38/58
By : Gaurav Narula
*uture State Maphe Steps
4$o "t5"mplement 2 "mplement 2 "mplement
Action 2 Action 2 Action 2 Action 2 Action
4#hec6 "t 2 Follow up5
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 39/58
By : Gaurav Narula
A simple way to
approach the FutureState Map is to begin
by modifying the
Current State Map.
*uture State Maphe Steps
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 40/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 41/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 42/58
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$
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 43/58
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,&
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 44/58
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
$3atch !rocess vs. *ontinuous %lo,&
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 45/58
By : Gaurav Narula
&is %uestion is as:ing were you will re%uiresupermar:ets or were you will a!e coupled
processes$
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 46/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 47/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 48/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 49/58
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?$*ontinued&
9 Fri9
Part D
Part C
Part A 8
Part D
Part D
2on9 -ue9 Wed9 -hu
&raditional Sceduling
Daily Production
Mon 104= Part D
&ue 104= Part D
?ed 104= Part D
&u 104= Part C
*ri 0/44 -=/ A
Le!el Sceduling
2on9 -ue9 Wed9 -hu9 Fri9
Part APart
Part CPart D
Part APart
Part CPart DPart A
Part Part C
Part DPart A
Part Part C
Part DPart APart
Part CPart D
Daily Production
Part A /-5Part 322
Part C 541
Part D /3//
2
Consider ;ey uestions
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 50/58
By : Gaurav Narula
Le!eling of te product mi' must be
supported by small lot production$
Small lot production must be supported by%uic: set"up$
6o, ,ill you level the production mi4 at the pacema5er process?$*ontinued&
Consider ;ey uestions
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 51/58
By : Gaurav Narula
An effecti!e way
of communicating
te le!el sceduleto manufacturing
operations can be
troug te use of
a load le!elingbo'$
6o, ,ill you level the production mi4 at the pacema5er process?$*ontinued&
Consider ;ey uestions
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 52/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 53/58
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?
$*ontinued&
Consider ;ey uestions
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 54/58
By : Gaurav Narula
Agenda Session +Revie! Current State 2a0
Design Future State 'ur0ose
Future State 2a0
Consider /ey 7uestions
Summary
A#tivity: Design Future State
C id ; ti
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 55/58
By : Gaurav Narula
Data is analy)ed todetermine waste
(inibitors to flow#$
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 56/58
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,
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 57/58
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
7/23/2019 Value-Stream-Mapping.pdf
http://slidepdf.com/reader/full/value-stream-mappingpdf 58/58
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+