value stream map
TRANSCRIPT
Value Stream Mapping of a Complete Product
What is Value Stream Mapping (VSM)?
• A ‘Value Stream’ (VS) is “all the actions (both value--added and non-value-added) currently required to bringa product through the main flows essential to everyproduct” (Rother & Shook, 1999, p. 3).
• Value Stream Mapping (VSM) is “the process of mappingthe material and information flows of all components and subassemblies in a value stream that includes manufacturing, suppliers, distribution and thecustomer”.
Power of Value Stream Mapping (VSM)
• VSM is a mapping tool that maps not only material flowsbut also information flows that signal and control thematerial flows.
• This visual representation facilitates the process for implementation of Lean Thinking by helping to identifythe value-adding steps in a value stream and eliminatingthe non-value adding steps, or waste (muda) in flowpaths of products.
An Example of a Current State Map
An Example of a Future State Map
Advantages of Value Stream Mapping
• Relates the manufacturing process steps to other componentsof the supply chain viz. distributors, suppliers andproduction control.
• Integrates material and information flows.
• Links Production Control and Scheduling (PCS) functionsto Shopfloor Control.
• Integrates various IE techniques for material and information flow analysis.
Disadvantages of Value Stream Mapping
• Fails to map multiple products that do not have identicalroutings.
• Fails to relate plant layout and/or material handlingto process and equipment parameters.
• Lacks any economic measure for “value”.
• Lacks the spatial structure of the facility layout.
• Biased towards high-volume low-varietymanufacturing systems.
• Fails to capture the time value (in $) of the flow delaysdue to setup, processing, queuing (at each process step),material handling, etc. delays due to capacity constraintsand order sequencing at each process step.
Basis for Value Network Mapping (VNM)
• Developed for products with complex BOM’s that have many components and several assembly levels.
• Developers of VSM state that “many value streams havemultiple flows that merge. Draw such flows over oneanother. But do not try to draw every branch if there aretoo many. Choose the key components first, and get theothers later if you need to” (Rother & Shook, 1999, p. 19).
Where to use Value Network Mapping
Raw
Materials
Finished
Goods
Pro
du
ctio
n F
low
s in
th
e
Ma
nu
fact
uri
ng
Sy
stem
s
C1 C3C2 C4 C5 C6 C7 C8 C9 C10
SA 2 SA 3 SA 4 SA 5SA 1
C11
COMPONENTS
SUB ASSEMBLIES
ASSEMBLIES
VSM APPLIES VERY WELL AT
THIS LEVEL
VNM APPLIES VERY WELL AT
THIS LEVEL
ASSEMBLY2
ASSEMBLY1
Our Goal
• To use our method to map the complete network of flowsfor a complex product or large sample of parts.
• To computerize basic Industrial Engineering (IE) tools formaterial flow mapping, using a software package formaterial flow analysis - PFAST (Production Flow Analysisand Simplification Toolkit).
• To integrate the material flow mapping power of PFASTwith a Finite Capacity Scheduling (FCS) software.
Fundamental Challenges in VNM
• How/where to locate the process boxes (representing the variousworkcenters) on the map without creating a “spaghetti look”?
• How to show the exact routing for (and identify) each value stream?
• How to identify the families of parts and sub-assemblies based onsimilarity of their manufacturing routings? � Group Technology!
• How to design a network of cells linked together into a POUS (Point Of Use Storage) factory layout to achieve “Flow”?
• Where to locate (i) the supermarkets to store groups of raw materials(ii) the supermarkets to store kits of parts for different sub-assemblies and (iii) the time buffers at the capacity constraints?
• How to schedule and synchronize the production of the different value streams that require capacity on common workcenters?
• How to compute the VAR (Value Added Ratio) for the entire network?
Value Network Map for a Machining Cell
EXERCISE
Problem Statement
How does one draw the Value Stream Map of a
single product given:
1. the Bill Of Materials (BOM) for the product,
2. the manufacturing routings for the
components, subassemblies and the final
product?
Overview of the Method for a Single Product
235701
235201
235202
235204
235205
235206
235207
235208
235209
235305
235102 SA
235101
235103 235203
235301
235302 235303 235304
BILL OF MATERIAL AND GOZINTO CHART FOR WOUND ROTOR
Indented BOM for the Product
• How/where to locate the process boxes (representing the variousworkcenters) on the map without creating a “spaghetti look”?
• How to show the exact routing for (and identify) each value stream?
• How to identify the families of parts and sub-assemblies based onsimilarity of their manufacturing routings? � Group Technology!
• How to design a network of cells linked together into a POUS (Point Of Use Storage) factory layout to achieve “Flow”?
• Where to locate (i) the supermarkets to store groups of raw materials(ii) the supermarkets to store kits of parts for different sub-assemblies and (iii) the time buffers at the capacity constraints?
• How to schedule and synchronize the production of the different value streams that require capacity on common workcenters?
• How to compute the VAR (Value Added Ratio) for the entire network?
Contents of a Value Network Map
Input Data to PFAST
763IRONW->763DRLPR->763WELDM->770WHLBR->771HCFIN->811ASMLY12TN20244416
764PSMAP->764PSMAO->763DRLPR->763WELDM->770WHLBR->771HCFIN->811ASMLY11TC201501-10515
763SHR16->761PUNCH->763PRBRK->764WELDM->763WELDM->770WHLBR->771HCFIN->811ASMLY11TB20197014
761PUNCH->761DBURR->761FORM2->761TWELD->761POLSH->761ASMLY->811ASMLY11TB10042313
761PUNCH->761DBURR->761HSTUD->761SPWLD->761ASMLY->811ASMLY12TB10041612
761PUNCH->761DBURR->761FORM2->761TWELD->761POLSH->761HSTUD->761SPWLD->761ASMLY->811ASMLY11TB100413-511
763BDSAW->763ACRO->763WELDM->770WHLBR->771HCFIN->811ASMLY14TA20196910
763BDSAW->763ACRO->771VIKIN->763WELDM->770WHLBR->771HCFIN->811ASMLY12TA2019689
763BDSAW->771VIKIN->763WELDM->770WHLBR->771HCFIN->811ASMLY12TA2019678
763SHR16->763IRONW->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY11T2022757
763SHR16->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY12T201972-67006
763SHR16->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY12T201972-43005
763SHR16->761PUNCH->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY11T201966-47384
763SHR16->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY11T201965-47383
763SHR16->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY13T201963-64312
763SHR16->763PRBRK->763WELDM->770WHLBR->771HCFIN->811ASMLY11T201962-65441
RoutingRevenueQuantityPartNo.
Q-type From-To Chart from PFAST
1764PSMAO
1764PSMAP
2761FORM2
2761TWELD
11761POLSH
4761ASMLY
3761SPWLD
3761HSTUD
22761DBURR
42761PUNCH
1764WELDM
3763DRLPR
21763IRONW
219763SHR16
111763PRBRK
23763WELDM
23770WHLBR
23771HCFIN
811ASMLY
62763BDSAW
42763ACRO
4771VIKIN
764P
SM
AO
764P
SM
AP
761F
OR
M2
761T
WE
LD
761P
OL
SH
761A
SM
LY
761S
PW
LD
761H
ST
UD
761D
BU
RR
761P
UN
CH
764W
EL
DM
763D
RL
PR
763IR
ON
W
763S
HR
16
763P
RB
RK
763W
EL
DM
770W
HL
BR
771H
CF
IN
811A
SM
LY
763B
DS
AW
763A
CR
O
771V
IKIN
W/C
PR Analysis Type II from PFAST
PR Analysis Type IV from PFAST
811ASMLY761ASMLY761POLSH761TWELD761FORM2761DBURR761PUNCHTB100423
811ASMLY761ASMLY761SPWLD761HSTUD761POLSH761TWELD761FORM2761DBURR761PUNCHTB100413-5
811ASMLY761ASMLY761SPWLD761HSTUD761DBURR761PUNCHTB100416
811ASMLY771HCFIN770WHLBR763WELDM763ACRO763BDSAWTA201969
811ASMLY771HCFIN770WHLBR763WELDM771VIKIN763ACRO763BDSAWTA201968
811ASMLY771HCFIN770WHLBR763WELDM771VIKIN763BDSAWTA201967
811ASMLY771HCFIN770WHLBR763WELDM763DRLPR764PSMAO764PSMAPTC201501-105
811ASMLY771HCFIN770WHLBR763WELDM763DRLPR763IRONWTN202444
811ASMLY771HCFIN770WHLBR763WELDM763PRBRK763IRONW763SHR16T202275
811ASMLY771HCFIN770WHLBR763WELDM763PRBRK763SHR16T201972-6700
811ASMLY771HCFIN770WHLBR763WELDM763PRBRK763SHR16T201972-4300
811ASMLY771HCFIN770WHLBR763WELDM764WELDM763PRBRK761PUNCH763SHR16TB201970
811ASMLY771HCFIN770WHLBR763WELDM763PRBRK761PUNCH763SHR16T201966-4738
811ASMLY771HCFIN770WHLBR763WELDM763PRBRK763SHR16T201965-4738
811ASMLY771HCFIN770WHLBR763WELDM763PRBRK763SHR16T201963-6431
811ASMLY771HCFIN770WHLBR763WELDM763PRBRK763SHR16T201962-6544
Parts
770WHLBR
771HCFIN
763WELDM
TB201990 TB600364-1
TC201989-1
TC202034 -1
510624370MN31004
MZ0901010035MZ0901010289
MZ0901010379MZ0909000050
TB100395
13640300A
MZ0901010091
MZ0901010166
TA800218
TN100429
TN100430
TN100432TB100408-5
TB100423TB100426
MZ060200142
TN201975
TN800587
TN800654
A14691400A TA800634 TB800629 - 7
811ASMLY
MZ0901020056
761ASMLY
771HCFIN
770WHLBR
763WELDM
TA201968 TA201969 TA201967 TC201501-105 TN202444 T201962-6544 T201963-6431 T201965-4738T202275-6544 T201966-4738
TA201974 TB201971 T201972-6700T201972-4300
761PUNCH
763PRBRK
763SHR16
764WELDM
763ACRO
771VIKIN
763BDSAW
764PSMAO
764PSMAP
763DRLPR
763IRONW
761PUNCH
763PRBRK
763SHR16
761SPWLD
761HSTUD
761DBURR
761PUNCH
761FORM2
761TWELD
761POLSH
Sub-netw ork 1
Sub-netw ork 2
Sub-netw ork 3
Aggregation of Value Streams into Sub-networks
Production Schedule for the Value Network Map
TB201990
TC201989-1
TC202034 -1
TB100395
TB100408-5
TB100413-5
MZ1304020031
TB100416
MZ1304020009
TB100423
MZ1304020009
811ASMLY (1.5)
770WHLBR (0.1)
771HCFIN (0.75)
763WELDM (2.5)
761ASMLY (0.1)
771HCFIN (0.5)
770WHLBR (0.1)
763WELDM (0.5)
TA201968
MZ1307010089
763ACRO (0.01)
771VIKIN (0.01)
763BDSAW (0.01)
TA201969
MZ1307020040
763BDSAW (0.017)
763ACRO (0.01)
TA201967
MZ1307010089
763BDSAW (0.01)
771VIKIN (0.01)
TC201501-105
MZ1302010028
764PSMAO (0.05)
763DRLPR (0.02)
764PSMAP (0.48)
TN202444
MZ1307010001
763IRONW (0.01)
763DRLPR (0.02)
T202275-6544
MZ1301010034
763IRONW (0.02)
763PRBRK (0.02)
763SHR16 (0.01)
T201966-4738
MZ1301010034
761PUNCH (0.02)
763PRBRK (0.03)
763SHR16 (0.01)
TB201971
TB201970
MZ1301010034
764WELDM (0.15)
T201972-6700
MZ1304010054
763SHR16 (0.01)
763PRBRK (0.01)
T201972-4300
MZ1304010054
763SHR16 (0.01)
763PRBRK (0.01)
761SPWLD (0.033)
761HSTUD (0.02)
761DBURR (0.002)
761PUNCH (0.017)
761FORM2 (0.007)
761TWELD (0.016)
761POLSH (0.01)
761DBURR (0.002)
761PUNCH (0.02)
761FORM2 (0.009)
761TWELD (0.031)
761POLSH (0.019)761PUNCH (0.1)
763PRBRK (0.02)
763SHR16 (0.01)
761DBURR (0.0005)
761PUNCH (0.005)11
12 13
1415
16
17 18 19
20
21
22C
max= 5.63 hours
7654321 T201965-4738
MZ1301010034
763SHR16 (0.01)
763PRBRK (0.02)
10T201963-6431
MZ1301010034
763SHR16 (0.01)
763PRBRK (0.02)
9T201962-6544
MZ1301010034
763SHR16 (0.01)
763PRBRK (0.02)
8
(1) Start with the job that has the Shortest Processing Time (SPT Dispatching Rule)
Tie Breaking Rule #1: Choose the job in the group (or subassembly) that has the Most Work Remaining (MWKR Dispatching Rule)
Tie Breaking Rule #2: Choose the job with the Smallest Job Index
(2) Repeat Step (1) until all jobs have been scheduled
764BDSAW 1 3 20.01 0.02 0.037
764PSMA 40.53
763ACRO 1 20.02 0.047
763DRPLPR 5 40.03 0.55
763IRONW 5 60.01 0.03
763SHR16 16 6 7 8 9 10 18 190.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11
771VIKIN 1 30.03 0.04
763WELDM 20 110.78 3.28
764WELDM 170.28
763PRBRK 16 18 19 6 7 8 9 100.13 0.14 0.15 0.17 0.2 0.22 0.24 0.26
761PUNCH 16 12 13 14 70.11 0.13 0.135 0.152 0.172
770WHLBR 20 110.88 3.38
761DBURR 12 13 140.132 0.1355 0.154
761FORM2 12 140.141 0.161
761TWELD 12 140.172 0.186
761POLISH 12 140.191 0.201
761HSTUD 150.211
761SPWLD 150.244
761ASMLY 210.344
771HCFIN 20 111.38 4.13
811ASMLY 225.63
Cmax = 5.63 hrs.
Explanation of the Gantt Chart:
(1) Jobs with same color code are the Completion Time (Ci) of each job at the same level (sub-assembly)
(2) Jobs with bold frame are the Makespan (Maximum Completion Time, Cmax) at each level (sub-assembly) in the (hierarchical) production schedule
Assumptions:
(1) Travel distances between workcenters are negligible and inter-operation transfer delays are zero. Ahem! Ahem!
(2) Changeover (or set-up) time for any operation is zero. Ahem! Ahem!
Acknowledgement:
The author gratefully acknowledges the assistance of ISE students (ISE533, Spring2005), Tom Chia and Dustin Converse, who developed the original version of this schedule
Facility Design using the Value Network Map
763SHR16 761PUNCH
763PRBRK
763/764WELDM 770WHLBR 771HCFIN
763IRONW
763DRLPR764PSMA
763BDSAW 763ACRO 771VIKIN
761DBURR 761FORM2 761POLISH 761HSTUD 761SPWLD
761ASMLY
811ASMLY
761TWELD
Preliminary Drawing of Value Network Map(without Sub-networks)
763SHR16
761PUNCH
763PRBRK 763/764WELDM 770WHLBR 771HCFIN
763IRONW 763DRLPR
764PSMA 763BDSAW
763ACRO 771VIKIN
761DBURR 761FORM2 761POLISH 761HSTUD 761SPWLD
761ASMLY
811ASMLY
761TWELD
Sub-netw ork 1
Sub-netw ork 2
Sub-netw ork 3
Final Drawing of Value Network Map(with Sub-networks)
811ASM761
POLSH
761
SPWLD
761ASY
761
DBURR
761
TWELD
761
HSTUD/
761PEM
761
FORM
761PUNCH
763SHR16 763PRBRK
763DRLPR
764PSMA
771
VIKIN
764/763 WELDM
763BDSAW
763ACRO
Sub-network 3
Sub-network 1
Sub-network 2
763IRONW
Point-Of-Use (POU) Facility Layout based on Value Network Map
Extension to Multiple Product BOMs
PRODUCT
A
PRODUCT
B
A1 A2 A3 B1 B2 B3
A
2-1
A
2-2
A
2-3
A
3-1
A
3-2
B
2-1
B
2-2
B
2-3
F1 F2 F3 F4
G1 G2
Relationship Between Different Product BOM's,Part Families (F), and Groups of Part Families (G)
Fi=Family of Parts Gj=Group of Part Families