currentvsm acme
TRANSCRIPT
Value stream
Value stream refer to all the activities yourcompany must do to design, order, produce, and deliver its products or service to customers.
Including value added and non-value added activities
A value stream has threemajor parts
The flow of materials, from receipt fromsuppliers to delivery to customers.
The transformation of raw materials into finishparts
The flow of information that supports anddirects both the flow of materials and thetransformation of raw materials into finish goods
Value Stream Mapping
Follow a product’s production path frombeginning to end, and draw a visual
1.
representation of every process in thematerial & information flows.
Then draw (using icons) a “future state”of how value should flow.
map2.
Example
Why use it?Allow every one to fully understand and agree on howvalue is produced and where waste occursHighlight the connections among activities and
information and material flow that impact the lead time ofyour value streamHelping to know the entire value stream instead of a single functionImproving decision-making process of understanding current practice in the companyCreate a common language and understanding by using standard symbolsAllow you to separate value-added activities from non- value added activitiesTo easy identify and eliminate areas of waste
Value Stream MangersEach Value Stream needs a Value Stream Manager
For product ownership beyond functions
Assign responsibility for the future state mapping and implementing lean value streams to line managers with the capability to make changehappen acrossboundaries.
functional and departmental
Value Streamreports to the
Managers should make their progresstop manger on site.
How do I create a value stream map
Assemble paper, pencils, erasers, and a stopwatch Select a product or service to map
Identify customer to identify takt time
Start to map – starting with customer requirements
Add production flow, materials flow, information flow, and icons
Create a lead time chart at the bottom, showing value added or non-added production lead time
Review it as a group
A few mapping tips
Always collect current-state information while walking along the actual pathways of materials and information flows yourself.Begin with a quick walk along the entire door-to- door value streamBegin at the shipping end and work upstreamBring your stopwatch and do not rely on standard times or information that you do not personally obtainMap the whole value stream yourself (a team)Always draw by hand in pencil
Using the Value Stream Mapping Tool
product family
Understanding how the shop floorcurrently operates. The foundationfor the future state.
Designing a lean flow.
plan andimplementation
future state drawing
current statedrawing
Focus on one product familyDetermine Product Families via:similar downstream “assembly” steps and equipment
Family product
Process Steps & Equipment
saw mill lathe Grind Ass. test Pack
P
R
O
D
U
C
T
LH X X X X X
RH X X X X X
Top X X X X X
Back X X X
X-y X X X X
Levels of a Value Stream
begin here
Process level
Single plant(door to door)
Multiple plants
Across companies
The Current State Map Exercise
Current State for Acme Stamping co.
Current State Drawingproduct family
Understanding how the shopfloor currently operates.
Material and Information flows
Draw using icons
Start
Have
with the “door to door” flow
to walk the flow and get actual
● no standard times
● draw by hand, with pencilplan andimplementation Foundation for the Future State
future state drawing
current state drawing
VSM - Material Icons
One process box equalsan area of flow. All processes should be labeled. Also used for departments, such asProduction Control.
ManufacturingProcess
Used to show customers,suppliers, and outside manufacturing processes
Outside Sources
Used to recordinformation concerning a manufacturing process, department, customer, etc.
Data Box
C/T = 45 sec
C/O = 30 min
3 shifts
2% Scrap
OutsideSource
process
VSM - Material Icons
Count and timeshould be noted.
Inventory
Note frequency ofshipments.
TruckShipment
Material that is producedand moved forward before the next process needs it; usually based on a schedule.
Movement ofproduction material by PUSH
Movement offinished good tothe customer
How often
VSM - Information Icons
For example; productionManual InformationFlow schedule or shipping
scheduleElectronic InformationFlow
For example: via electronicdata interchange (EDI).
Describes an informationflow.
Information
Adjusting schedules based onchecking inventory levels.
“Go See” ProductionScheduling
Tool to intercept batches ofkanban and level the volumeand mix of them over aperiod of time.
Load Leveling
Indicates a device to limitquantity and ensure FIFO flow of material betweenprocesses. Maximum quantity should be noted.
max. X piecesFirst-in first-outflow
WeeklySchedule
Acme stamping Co. case study
The layout and process informationcompany
Icons references
A legal size paper for your exercise
Work along in the class
of Acme
This considered as in-class homework(individually) – due today
2
1 3
4 5
Step 1- customer icon
State StreetAssembly
18,400 pcs/mo
-12,000 “L”
-6,400 “R”
Tray= 20 pieces
2 Shifts
Step 2: all processes, data boxes, andinventory triangles
I1600LH850 RH
I4600L
2400R
I2700
L
1440R
ICoils5
days
I I1200L
640R
1600LH850 RH
Shipping
STAGES
Assembly #2
1
C/T=40 seconds
C/O= None
Uptime 100%
2 Shifts
27,600 sec. avail.
Spot Welding #2
1
C/T=46 seconds
C/O= 10 minUptime 80%
2 Shifts
27,600 sec. avail.
Spot Welding
1
C/T=39 seconds
C/O= 10 min
Uptime 100%
2 Shifts
27,600 sec. avail.
Stamping
1
C/T=1 secondsC/O= 1 hr
Uptime 85%
EPE 2 wks
27,600 sec. avail.
Assembly #1
1
C/T=62 seconds
C/O= None
Uptime 100%2 Shifts
27,600 sec. avail.
State StreetAssembly
18,400 pcs/mo
-12,000 “L”
-6,400 “R”
Tray= 20 pieces
2 Shifts
Step 3: show the material flow
Control
Steel Co.
I4600L2400R
I2700
L
1440R
ICoils5
days
I I1600LH
850 RH
I1600LH 1200L850 RH 640RC/T=39 seconds
27,600 sec. avail.
Shipping
STAGES
Assembly #2
1
C/T=40 seconds
C/O= None
Uptime 100%
2 Shifts
27,600 sec. avail.
Assembly #1
1
C/T=62 seconds
C/O= None
Uptime 100%
2 Shifts
27,600 sec. avail.
Spot Welding #2
1
C/T=46 seconds
C/O= 10 minUptime 80%
2 Shifts
27,600 sec. avail.
Spot Welding
1
C/T=39 seconds
C/O= 10 min
Uptime 100%
2 Shifts
27,600 sec. avail.
Stamping
1
C/T=1 seconds
C/O= 1 hr
Uptime 85%
EPE 2 wks
1xDaily
Tues + Thurs
500 ft coils
Michigan
Production
MRP
State StreetAssembly
18,400 pcs/mo
-12,000 “L”
-6,400 “R”
Tray= 20 pieces
2 Shifts
Step 4: show the information flow
Steel Co.
Thurs
I4600L
2400R
I I2700
L
1440R
ICoils5
days
I I1600LH 1600LH
850 RH1200L
850 RH 640R
27,600 sec. avail.
C/T=39 seconds
Shipping
STAGES
Assembly #2
1
C/T=40 seconds
C/O= None
Uptime 100%
2 Shifts
27,600 sec. avail.
Assembly #1
1
C/T=62 seconds
C/O= None
Uptime 100%
2 Shifts
27,600 sec. avail.
Spot Welding #2
1
C/T=46 seconds
C/O= 10 minUptime 80%
2 Shifts
27,600 sec. avail.
Spot Welding
1
C/T=39 seconds
C/O= 10 min
Uptime 100%
2 Shifts
27,600 sec. avail.
Stamping
1
C/T=1 secondsC/O= 1 hr
Uptime 85%
EPE 2 wks
1xDaily
Tues +Daily ShipSchedule
Weekly Schedule
500 ft coils
Michigan
ProductionControl6-week Forecast
Weekly faxMRP
State StreetAssembly90/60/30 day
Forecasts18,400 pcs/mo
-12,000 “L”
-6,400 “R”
Daily order
Tray= 20 pieces
2 Shifts
Step 5: Add lead and value-add time chartidentify lead time
Demand: LH: 12,000/month = daily 12000/20=600 RH: 6400/month = daily 6400/20 = 320
Station LH – inv. L.T. RH – inv. L.T. Max.
Stamping 4600 7.6 2400 7.5 7.6S. Weld #1 1100 1.8 600 1.9 1.9S. Weld #2 1600 2.7 650 2 2.7Ass. #1 1200 2 640 2 2Ass. #2 2700 4.5 1440 4.5 4.5Total lead time (add 5 days for Coils) 23.7
Step 5: Add lead and value-add time chart
Steel Co.
Thurs
I4600L
2400R
I2700
L
1440R
ICoils5
days
I I I1600LH 1600LH
850 RH1200L
850 RH 640R
27,600 sec. avail.
4.5 days5 days 7.6 days 1.9 days 2.7 days 2 days
39 s 62 s 40 s1 s 46 s
C/T=39 seconds
L.T. 23.7 days
P.T. 188 seconds
Shipping
STAGES
Assembly #2
1
C/T=40 seconds
C/O= None
Uptime 100%
2 Shifts
27,600 sec. avail.
Assembly #1
1
C/T=62 seconds
C/O= None
Uptime 100%
2 Shifts
27,600 sec. avail.
Spot Welding #2
1
C/T=46 seconds
C/O= 10 minUptime 80%
2 Shifts
27,600 sec. avail.
Spot Welding
1
C/T=39 seconds
C/O= 10 min
Uptime 100%
2 Shifts
27,600 sec. avail.
Stamping
1
C/T=1 secondsC/O= 1 hr
Uptime 85%
EPE 2 wks
1xDaily
Tues +Daily ShipSchedule
Weekly Schedule
500 ft coils
Michigan
ProductionControl
6-week Forecast
Weekly faxMRP
State StreetAssembly90/60/30 day
Forecasts18,400 pcs/mo
-12,000 “L”
-6,400 “R”
Daily order
Tray= 20 pieces
2 Shifts