VSM- Learning To Lean. How to implemented on professional & Business area

Related on VSM topics

2. LEARNING TO SEE

mie Cobras

3. mie Cotbrata Toño EG

4. mie Cotbrata Toño EG

5. intel She e Toño Met

7. intel She e Toño EG

8. intel She e Toño EG

9. intel She e

10. intel She e Toño Met

11. aay | En AAA

4 Sake I ] ETT ER
AAN reg .

raté
ENEE

in

al

za ER ps e
Sora

A Current-State
Value Stream Map

12. Frosscnon |

cor Beat CONTROL | nr
Suppliers | Ordes +__x ¡E à
E Distri hubo
br cas Orders a

we
Y

=
ie AA
| a Value Stream Map

13. ke Cowie e

14. mie Cotbrata Toño EG

15. mie Cotbrata Toño EG

16. |

17. intel She e Toño Met

18. PRODUCTION FLOW

To create value adding flow you need a “vision.
Mapping helps you see and focus on flow with a vision of
an ideal or improved state.

tS
a

mie Cotbrata Toño EG

19. Fay

20. nie Gee eee

intel She e Toño EG

21. JOB DESCRIPTION FOR A

VALUE STREAM MANAGER

* Reports lean implement-
ation progress to the top
person on site

+ Aline, not staff, person
with the capability to make
change happen across
functional and
departmental boundaries

+ Leads the creation of the
current-state and future-
state value stream maps
and the implementation
plan for getting from
present to future

+ Monitors all aspects of
implementation

+ Is present at the implement-
ation site every day

+ Makes implementation a tons
top priority

+ Maintains and periodically
updates the implementation
plan

+ Insists on being a hands-on
person driven by results

two kinds of Kaizen

mie Cotbrata Toño EG

22. >
a=

work plan &
Implementation

Initial Value Stream
Mapping Steps

intel She e Toño Met

23. SUMMARY - YOUR STARTING POINT

> Select a product family

> Have one person personally lead the mapping effort

> Begin at the “door-to-door” level

> Consider both the material and information flows

mie Cotbrata Toto

24. Part Il: THE CURRENT-STATE MAP
» Drawing the Current-State Map
» Your Turn

Ss

4

Ete hei Reis Met

25. rada tho Gone Sans Dep

single plant
(door to door)

multiple plants

intel She e Toño Met

26. a

27. Always draw by hand in pencil.

Drawing by hand can be done without delay, while you are on the floor. As you
draw you will think of further information that you need.

Drawing by hand means that you can do it yourself, which is key to
understanding the material and information flows.

Drawing by hand means you will focus on understanding the flow, instead of on
how to use the computer. The point of value stream mapping is not the map, but
understanding the flow of information and material.

Having to manually fine-tune your drawings will improve your mapping ability.
Keep an eraser handy!

s

intel She e Toño Met

29. intel She e Toño Met

30. State Street
Assembly

18,400 pcs/mo
-12,000 “L”

- 6,400 “R”

Tray = 20 pieces
2 Shifts

Sy de Goer

intel She e Toño Met

31. intel She e Toño Met

32. Material flow is drawn from left to right on the bottom half of the map in the order of
processing steps; not according to the physical layout of the plant. At Acme
Stamping we find six processes in the steering bracket material flow, which occur in
the following order:

Stamping

> Spot-Welding Workstation 1
Spot-Welding Workstation 2
Assembly Workstation 1
Assembly Workstation 2
Shipping

vvvv

vv

intel She e Toño Met

33. intel She e

To help you get started here is a
list of typical process data:

Y C/T (cycle time)

Y C/O (changeover time)

y uptime (on-demand
machine uptime)

y EPE (production batch
sizes)

y number of operators

v number of product
variations

Y pack size

v working time (minus
breaks)

y scrap rate

35. Some Lean Measurements

Cycle Time der

LUE
DODODOODO ceenmecmn

VA Time

oookoo DD Value Added Time (va)

Usually: VA < C/T < UT

Die Makel | Rus 542

36. STAMPING S. WELD #1 A 8. WELD #2
1

200T
es 1100 L
© 60OR

CIT = 46 seconds
CIO = 10 minutes

EPE = 2 weeks 27,600 sec. avail. 127,600 sec. avail.

Gel Colère a rain ENE

37. -12,000
- 6,400 “R”

Staging

Uptime =100%
27,600 sec. avail

a Rss Main

Ci0= Y

38. WELD #1

40. AA

42. Michigan
SteelCo,

PRIT
CONTROL

ver

TI Weekly Schedule

Fourth View of the Current-State Map
with Information Flows & Push Arrows

FANS

AA

EXT

TE |

1

ef

CIO= 0 minutes |

43. intel She e Toño Met

44. 2 hours
40 seconds

” GO Look!

intel She e Toño Met

45. AG oncende

46. mie Cotbrata

47. mie Cotbrata Toño EG

48. intel She e Toño Met

49. intel She e Toño Met

50. mie Cotbrata Toño EG

51. intel She e Toño Met

52. intel She e Toño Met

53. Part Ill: WHAT MAKES A VALUE STREAM LEAN?
» Overproduction

» Characteristics of a Lean Value Stream

intel She e Toño Met

54. intel She e Toño Met

56. intel She e Toño Met

57. intel She e Toño Met

58. ak eh —

mie Cotler Toño EG

60. Rua = Gottuleage lft) Toño sel

61. “production"KANBAN “withdrawal"KANBAN

product product

SUPERMARKET

Ete Gobeil « Reis Meg)

62. There is another icon
similar to the supermarket
icon, but closed on all
sides. This icon
represents “safety stock,”
which is used as a hedge
against problems such as
G ) downtime, or “buffer
stock,” which is used to

Withdrawal Production Kanban Arriving
Kanban in Batches

sudden fluctuations in
customer orders. Safety
stock should be temporary
-- used only until the root
cause of a problem is
found and eliminated. To
Supermarket Withdrawa! K ig ensure that safety stock
kanben does not

intel She e Toño Met

63. intel She e Toño Met

64. ©

intel She e Toño Met

65. Supermarket

GE «© Gp O Pace La | Reis Met

66. intel She e Toño Met

67. e
Y i
Se ee „u oe CS SE ET
[JA FE Fe

en

GE Makel «€ Rus MEG

68. intel She e Toño Met

69. intel She e Toño Met

71. NN

72. Mean

73. intel She e Toño Met

74. Part IV: THE FUTURE STATE MAP
> Drawing the Future-State Map

> Your Turn

GE) Cire « Mato

75. product family

current-state
drawing

intel She e Toño Met

76. Rua = Gottuleage lft) Toño sel

77. intel She e Toño Met

78. intel She e Toño Met

79. Available Working Time: 28,800 - 1200 = 27,600 seconds per shift

Available Working Time 27,600 sec. + 460 units per shift
Customer Demand

Acme Steering Bracket Takt Time = 60 seconds

intel She e

Note

Try to cycle your pacemaker
process as close as possible
to takt time. A significant
gap between takt time and
cycle time indicates the
existence of production
problems that cause
unplanned downtime. When
you compensate for
production problems by
cycling much faster than
takt, the incentive to
eliminate those problems
evaporates. If you cycle
faster than takt there should
be a plan for closing the

gap.

80. E SS ee ee ee ge. ee

Rua = Gottuleage lft) Toño sel

81. GE Haken Mm Chats 542

82. asa neh y» ‘Previous 569

83. intel She » Reis Mo

84. takt time
60
seconds

2 2
3 3
£ A
ö A]
N] a
Y a
0 8

Die Sb “Reis Met

85. Rua Chez A

at ©

86. o
£
=
x
8

o
H
©
83
©
o

eiquiosse

intel She e

87. First Viow of the Future-State Map Showing
Takt Time, Weld/Assombly Cell, and the
Finished-Goods Supermarket

Gel Colère a rain ENE

88. intel She e Toño Met

90. Drawn with icons, the flow now looks

batch
7

\/---

Every 600 UH
‘or 820 RH
WELD +

91. intel She e Toño Met

92. co EL

intel She e Toño Met

93. AAA

State Street
Assembly

ET PRODUCTION
rorecset CONTROL

[8.400 promo
~12000 1
8400

Second View of the Future-State Map
Showing Stamping and Raw Material

Eis

Samen H WE + ser.

94. intel She e Toño Met

95. Rua Chez A Toño EG

96. intel She e Toño Met

97. E

Rua Chez A

98. PRODUCTION
CONTROL
Daily Order

batch of kanban ——> €?

one kanban at Option A

99. intel She » Reis Mo

100. PRODUCTION
CONTROL

batch of kanban

one kanban
at a time Daily Order

| r-LOXOK|-- 205

zo Option B

EX Ta

: A
É
M a G ae:

101. Rua Chez A Toño EG

102. per product

asa neh y» ‘Previous 569

103. intel She » Reis Mo

104. intel She » Reis Mo

105. Michigan
Steel Co.

PROBICHON

CONTROL | og
+—

Dally Order,

| state street
Assembly

106. intel She »

107. intel She e Toño Met

108. Your Turn

Before you head off to create the future state for your own value streams -- which we hope and trust you will do
very shortly -- you may need some practice. We invite you to take another clean sheet of paper and draw a future-
state value stream map for the “TWI Industries” example on page 43 you used to practice creating a current-state
value stream. You can compare your future-state map with our may by turning to Appendix C.

Remember that what is “right” in terms of a value stream map is one that permits you to quickly remove root
causes of waste. Therefore, please take our map and mapping techniques as a provocative suggestion and revise
the basic ideas to suit your particular needs.

intel She e Toño Met

109. Part V: ACHIEVING THE FUTURE STATE

» Breaking Implementation Into Steps

- The Value Stream Plan |

» Value Stream Improvement is
Management's Job

©

intel She e Toño Met

111. Base platon lato Ses

intel She » Reis Mo

112. Supplier Loop

An Example of
Value Stream Loops

113. intel She » Reis Mo

114. Rua Chez A Toño EG

115. A, x
je | ai

Supplier Loop a

Acme's Value
Stream Loops

116. intel Goble) mw Toño Met

117. intel Goble) mw Toño Met

118. intel Goble) mw Toño Met

119. intel She e Toño Met

120. É JANZ,1998 Signatares
ps ere

Bonino Objective, sam MONTHLY SCHEDULE ween [sous

Improve
me wale Ve 100%
Fami | 2unera

121. intel Goble) mw Toño Met

122. intel Goble) mw Toño Met

124. intel Goble) mw Toño Met

125. Rua Chez A Toño EG

126. intel She e Toño Met

127. Value Stream Value Stream Value Stream
Manager Manager Manager

Lean

Specialists

intel She e Toño Met

128. CE a hee ee a
SRG times ADA
Pa
Sew tigi wee roe mc
Te ey el

intel She e Toño Met

129. intel Goble) mw Toño Met

130. intel Goble) mw Toño Met

131. TAKE THE

LEAN LEAP A
ED)

Je

intel Goble) a Toño Met

132. intel Goble) mw Toño Met

136. intel She e Toño Met

137. intel Goble) mw Toño Met

139. Ete Gobeil « rats Metal

140. intel Goble) mw Toño Met

141. intel She e Toño Met

142. intel Goble) mw Toño Met

143. intel She e Toño EG