8--Value-Stream-Mapping-Slides-3-19-09

ValueStreamAnalysis2Agenda•HighLevelOverviewofValueStreamAnalysisandProcessMapping•StepstodevelopaCurrentStateValueStreamMap•HighLevelOverviewofFutureStateDesign3ValueStreamAnalysis“Wheneverthereisaproductforacustomer,thereisavaluestream.Thechallengeliesinseeingit.”Completedescriptiveanalysisofprocessflowsandadetailedbreakdownofvaluetowardsthefinalproduct“BlueprintforImprovements”QuotefromWomack&JonesDefinitionofValueStreamAnalysis4WhyisValueStreamAnalysissoimportant?ƒSupportstheoverallvisionofacompanyƒShowstheconnectionofmaterial,people,andinformationflowsƒVisualizeswasteandobstacles,andsupportstotalcostanalysisƒStandardformanagementtodocumentthewholeprocessƒValueStreamAnalysisprevents“silothinking”ValueStreamAnalysisACurrentStateMapisapictorialviewshowinghowmaterialandinformationflowthroughanoperation,department,section,entireplantand/ormultipleplantsWhatisaCurrentStateMap?6HighLevelandLowLevelMapsA“HighLevel”mapisa“10,000ftview”ofaplantorprocess.A“LowLevel”mapisa“5,000ftview”ofaplantorprocessusuallyfoundwithinthe“HighLevel”map.MeltingFormingShippingFiberizingPaperInstallTrimmingInspectionSupplierXCustomerYCastingCustomerY7CurrentStateMapExampleƒItalignseveryone’sunderstandingofhowthecurrentproductionsystemreallyoperatesƒItcreatesabaselineonwhichfutureimprovementswillbemeasuredƒItisavisualrepresentationofmaterial,information,andtimeflowsandprovidesamethodoforganizingthedataƒIthelpstoexposeswasteƒIttakesthe“negativeemotion”outofitƒProvidethefirststepinlaunchingStabilityWhydoweuseaCurrentStateMap?ƒDefinition-Avisualrepresentationofthe“perfected”product,processandinformationflow-Wastehasbeenremoved-Synchronousflowofmaterialachieved-ProductispulledinaleveledmannerƒTiestogetherleanconceptsandtechniquesƒDrivenbyCustomerDemandƒUsedtodriveadetailedimplementationplanWhatisaFutureStateMap?10•describesaprocessasitworkstoday-“AsIs”Model•showsthe“bigpicture”•ishightouch,low-tech•identifiesstrengthsandopportunities•capturesthecomplexityanddisconnectsofkeyoperationalissues•identifiesoutsideareasinvolvedinprocessWhatisaBrownPaper?11•Provokethoughtforimprovementopportunities•Promotecommonunderstanding-increasedcross-functionallearning•Trainnewemployeesonprocess•Useasapresentation/storytellingtoolABrownPaperisaneffectivemethodfordocumentingthe“AsIs”processandidentifyingimprovementopportunitiesWhyBuildABrownPaper?12ProcessAccordingCOULD-BETO-BESHOULD-BE•ActualProcessinUseToday•toProcedures•IdealState•ModelforImplementationAS-ISACloserLookattheDefinitionof“AsIs”vs.“ShouldBe”13ValueStreamAnalysis•Summary–ValueStreamAnalysisisapowerful,flexible,visualtool,whichenableseverbodytointerpretthestepsofaprocess,andhighlighttheleadtimeandthewasteitcontains–Theflowchart,ifkeptdynamic,willhelptoprioritizeKaizenactivitiesanddevelopactionplansforimplementingleanstrategicallyintoanorganization14ValueStreamMappingCurrent-statemappingLeanfuture-statedesignImplementationplanning&executionƒMapthecurrentvaluestreamshowingthematerialandinformationflowsƒMeasure/observelean-implementationprocessdataƒDesignthefutureleanstateƒMapfuture-statematerial&informationflowsƒSegmenttheflowinto“loops”forimplementationplanningƒDevelopimplementationplanwithschedule,ownersandmeasurablemilestonesandresultsƒExecuteplanTop-LevelMapping,LeanDesignandImplementationProcessMapCurrentStateValueStreamMapping16LeanThinkingTheFundamentalInsight•Focusoneachproductfamilyanditsvaluestreamratherthantheorganization,it’sassetsandtechnologies•Askwhichactivitiesarewasteandwhichtrulycreatevalue•Thenenhancethevalueandeliminatethewaste!17ValueStream•Avaluestreamisthesetofactivitiesrequiredtodeliveraproducttothecustomerfromrawmaterialinput•Inmanycasesthetotalvaluestreamencompassesmultiplecompaniesandplants•Agoodstartingpointistoworkatthe“door-to-door”levelwithinaplant.Thiskeepstheprojectatmanageablelevelofcomplexitybutretainsasufficient“big-picture”scope•A“big-picture”scopeisrequiredtoavoidselectiveimplementationresultinginisolatedislandsofleanwithinanon-leanprocess18ValueStreamTotalValueStreamTotalValueStreamOrderOrderDeliveryDeliveryConceptConceptLaunchLaunchRawRaw--materialsmaterialsCustomerCustomerActionActionMultiMulti--plantplantActionActionPlantPlantActionActionAction19ValueStreamMapping•Avalue-streammapisamapofthematerialandinformationflowsinaproductfamily’svaluestream•Ithelpsustoeffectivelyimplementleanby:•Givingusa“big-picture”viewofthecurrent-statevaluestreamandit’ssourcesofwaste•Providingusacommonlanguagefortalkingaboutmanufacturingprocesses•Identifyingspecificimprovementsinspecificareastoenablelean•Showingthelinkagebetweeninformationflowandmaterialflow•Facilitatingthevisionanddesignoftheleanfuture-statevaluestream,i.e.itprovidesablueprintfortheleanfuturestate20Example:Current-StateVSMSupplierCustomerProductdeliverySupply-chaindataDemand-patterndataProcess1dataProcess2dataProcessndataInventoryquantityInventoryquantityInventoryquantityInventoryquantityProductioncontrolProductionscheduleProductionscheduleProductionscheduleForecastsRaw-MaterialForecastsOrdersRaw-materialorder