Value stream mapping

Value Stream Mapping

Value Steam Mapping

The Value Stream - a definition
“All of the steps required to bring a product or service from raw state through to the customer”
Total Value Stream

Supplier

Process C

Process B

Process A

Customer

Internal Plant

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Value Steam Mapping

What is Value Stream Mapping?
Value Stream Mapping is a powerful technique that allowsus to create a “BIG PICTURE” visual representation of: – All the steps in the process, working back from customer demand to raw material – The flow of both material and information and the effect they have on each other – The distinction between value-added and non-valueadded activity (WASTE) – The effect all of the above have on meeting the customer’s requirements

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Value Steam MappingThe 8 Wastes

Scrap/Rework

Over-production

Inventory

Motion

Processing

Transportation

Under-utilized People Waiting (manpower, material, machine)
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Value Steam Mapping

#1 Scrap/Rework
Definition:
– Any product that does not meet specifications and therefore either needs to be reworked or scrapped

Goal:
– 100% First Time Through Quality

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Value Steam Mapping#2 Over-production (Under)
Definition:
– Producing more than is necessary, often causing WIP (Work In Process); working on parts ahead of schedule while delinquent parts wait

Goal:
– Produce to Target Cycle Time then eventually produce all operations to Takt Time in the Future State

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Value Steam Mapping

# 3 Inventory
Definition: material or parts that are stored for futureuse or shipment

Before

After

If you had only 30 seconds to find the unit… ...which storage system would you choose?
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Value Steam Mapping

#4 Motion
Definition:
– Excessive motion beyond what is needed to get the job done

Goal:

Same as Definition

???

sitting

searching

turning around

walking

climbing

choosing

bending lying down over
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Value SteamMapping

#5 Processing (Over & Under)
Definition:
– Extra and/or unnecessary operations – Standardization of operations not thorough enough – Processing a part above specifications

Goal:
– Process parts that consistently meet the minimum customer requirements 100% of the time
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Value Steam Mapping

#6 Transportation
Definition:
– Moving parts to unnecessary distances from oneoperation to another

Goal:
– Put operations in order; minimize or eliminate the travel distance between them

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Value Steam Mapping

#7 Waiting
Definition:
– a person or part(s) sitting idle while waiting for material, a supervisor, the next operation, etc.

Goal:
– Eliminate the unplanned interruptions that occur due to inefficiencies – Develop continuous flow wherever possible –Convert waiting to valueadded work

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Value Steam Mapping

#8 Under-utilized People
Definition:
– Skills untapped, Ideas not implemented and improvements not realized

Goal:
– Tap into the energies and unused improvement ideas from the workforce

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Value Steam Mapping

Exercise Worksheet
MANUFACTURING WASTES IDENTIFICATION SHEET
Dept: _______________
TransportationUnder-utilized People Scrap/Rework Over (Under) Production Processing
5S - Sort, Straighten, Sweep, Standardize & Self Discipline

Inventory

NO.

WASTE IDENTIFIED

John McLauchlin

Revision Date: 4/25/2000

Waiting

Motion

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Value Steam Mapping

Value Stream Analysis Process
Value Stream Mapping 1.0 Select Champion and Initial Product Family 2.0 Gather, Map, and Analyze SelectedValue Stream Data 3.0 Design Future State 4.0 Implementation Planning and Execution

1. Understand business goals and customer objectives 2. Select champion and value stream leaders based on proven criteria for success 3. Define product families based on common processes and equipment

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Value Steam Mapping

Leadership and Champions
Observations

Lean Aerospace Initiative

– A...