ValueStreamMappingRecognizingtheValue-Addedstepsinyourprocesses1CI-GT-015REV.0RecommendedReadingLearningtoSee

byMikeRotherandJohnShook2CI-GT-015REV.0LevelsofValueStream3CI-GT-015REV.0SupplyChaina.k.aValueStreamTotalValueStreamSuppliersXxxBranch(es)CustomertoConsumerToday4CI-GT-015REV.0ValueStreamMappingValueStream-Allsteps,valueaddedandnonvalueadded,requiredtobringtheproductfromrawmaterialtocustomer.5CI-GT-015REV.0WhatisaValueStreamMap?AdetailedflowchartAbigpictureperspective–improvingthewhole,notjustoptimizingthepartsandmaybesub-optimizingthewholeWewillfocusonthedoor-to-doorproductioninsideaplantHelpsyouseeandunderstandtheflowofmaterialandinformation6CI-GT-015REV.07CI-GT-015REV.0ValueStreamMapping8CI-GT-015REV.09CI-GT-015REV.0BenefitsofValueStreamMapping10CI-GT-015REV.0MaterialandInformationFlowsMaterialflowthemovementofmaterialthroughthefactoryInformationflowanotherflowassociatedwithproductionthattellseachprocesswhattomakeordonext11CI-GT-015REV.0ValueStreamMappingStepsProductFamilyCurrentStateDrawingWorkPlanFutureStateDrawing12CI-GT-015REV.0ValueStreamMappingStepsChooseaproductfamilyBeginbydrawingthecurrentstate(door-to-door)GatherinformationfromtheshopfloorDevelopmentofcurrentstateandfuturestateareoverlappingeffortsPrepareandbeginusinganimplementationplanRepeatwhenfuturestatebecomescurrentstate13CI-GT-015REV.0ProductFamily14CI-GT-015REV.0GatherDataManufacturingTransactional/Office15CI-GT-015REV.0TypicalProcessDataCycletimeChangeovertimeProductionbatchsizesNumberofproductvariationsNumberofoperatorsPacksizeWorkingtime(minusbreaks)ScraprateOn-demandmachinetime16CI-GT-015REV.0MaptheFlowofItemsusethisboxtorepresenteachprocessstepusethissymbolforcustomersandsuppliersusethissymboltorepresenta"supermarket"(first-in-first-out)PROCESSnotesanddetailsEXTERNALPLACESusethissymbolforstoredinventory(knownquantities)usethissymbolforpushedinventory(arrowimpliesWIP)usethissymbolforapullsystemusethissymbolforafirst-in-first-outflow"lane"usethissymbolfortransportationIFIFOmax1017CI-GT-015REV.0MapFlowofInformationusethissymbolformanualflowofinformationusethissymbolforelectronicflowofinformationusethissymboltorepresentinformationthatflows(suchas"schedulesequence")usethissymbolforpullsystempapertriggerusethissymbolforapullsystemreturnablecontainertriggerusethissymbolforpullsystemtriggerataparticularquantitylevelusethissymbolforpullsystem"gosee"triggerusethissymbolforpullsysteminformationstoragepointsinformation18CI-GT-015REV.0MappingTipsAlwayscollectcurrent-stateinformationwhilewalkingtheactualmaterialandinformationflowsyourself.Startwithaquickwalkalongtheentiredoor-to-doorvaluestream–thengobackandgatherdataateachprocessBeginattheshippingendandworkupstreamMeasureyourowntimes–don’trelyonstandardtimes,olddatainafile,orhearsayEvenifseveralpeopleareinvolved,mapthewholevaluestreamyourselfUsebutcherpaperandmarkers19CI-GT-015REV.0CurrentStateValueStreamMap20CI-GT-015REV.0CurrentStateMap–BytheNumbersStartwiththecustomer–placeintheupperright-handcornerofthemapShowthecustomer’srequirementsinadataboxDrawthebasicproductionprocesses–indicateaprocessbyusingaprocessbox–drawmaterialflowfromlefttorightonthebottomhalfofthemapCollectdatathatwillbeimportantfordecidingwhatthefuturestatewillbe–drawadataboxundereachprocessbox21CI-GT-015REV.0ValueStreamMap22CI-GT-015REV.0ValueStreamMap23CI-GT-015REV.0CurrentStateMap–BytheNumbersNoteplacesinthematerialflowwhereinventoryaccumulates–drawaninventorytriangletonotethelocationandamountofinventoryDrawthemovementofproducttothecustomerandnotefrequencyDrawthesupplier(s)intheupperlefthandcornerofthemap–notepacksizeanddeliveryfrequency24CI-GT-015REV.0CurrentStateMap–BytheNumbersDrawtheinformationflowfromrighttoleftinthetophalfofthemapShowtheinformationflowusinganarrowthatislabeledwithnode-box–thisnodedescribestheinformationflowarrowUseseparatelinefordifferentinformationflows(e.g.,forecastsanddailyorders)Useaprocessboxtodenoteanyprocesseswithintheinformationflow25CI-GT-015REV.0CurrentStateMap–BytheNumbersUseastripedarrowinthematerialflowpartofthemaptodenoteapushmovementofmaterialDrawatimelineIdentifymaterialmovementsthatarepushedbytheproducer,notpulledbythecustomer–thiscanbedoneasyoufigureouthoweachprocessknowswhattomakeforitscustomerprocessandwhentomakeitDrawatimelineundertheprocessboxesandinventorytrianglestocompiletheproductionleadtime26CI-GT-015REV.0ProductionLeadTimeTheleadtimecomponentforaprocessboxisthecycle-timeforaparttogothroughtheprocessLeadtimes(indays)foreachinventorytrianglearecalculatedas:(inventoryquantity)x(takttime)/(availableworktimeperday)27CI-GT-015REV.0ATaktTimeReminderTakttime=(youravailableworktimepershift)/(customerdemandpershift)Availableworkingtimeexcludesbreaks,lunch,etc.andisrecordedinsecondsCustomerdemandisrecordedinunitsorpiecesTakttimedenotestherateatwhichacustomerbuysoneproduct28CI-GT-015REV.0TIMELINECreateatimelineacrossthebottomofyourValueStreamMapTheUppertimeshouldbeyourNon-ValueaddedtimeortheamountoftimetheproductiswaitingforprocessingTheLowertimeshouldbeValueAddedtimeortheamountofprocessingtime29CI-GT-015REV.0WasteTheelementsofproductionthataddnovaluetotheproduct.Thingstorememberaboutwaste:Wasteisreallyasymptom,notarootcauseWastepointstoproblemsinthesystemToeliminatewaste,findandaddresstherootcause30CI-GT-015REV.0Activity≠ProductivityThe8DeadlyWastesOverproductionProductDefectsInventoryExcessProcessTransportationExcessMotionWaitingUnder-utilizingPeopleEverybody'sbusy!Butwearestillnotdelivering!Wheredoesallthateffortgo?31CI-GT-015REV.0Howmanyoperators?32CI-GT-015REV.033CI-GT-015REV.0QuestionsfortheFutureStateWhatisthetakttime,basedontheavailableworkingtimeofyourdownstreamprocessesthatareclosettothecustomer?Wherecanyouusecontinuousflowprocessing?Whatisthepacemakerproductionprocessthatyouwillschedule?Wherewillyouneedtointroducesupermarketpullsystemsinordertocontrolproductionofupstreamprocesses?34CI-GT-015REV.0SomeDefinitions(viaanExample)Process1Process2Process3Process4CustomerOnePieceFlowFIFOlanePullSupermarketPacemaker35CI-GT-015REV.0QuestionsfortheFutureStateWillyoubuildtoafinishedgoodsupermarketfromwhichthecustomerpulls,ordirectlytocustomerorder?Howwillyouleveltheproductmixatthepacemakerprocess?Whatincrementofworkwillyouconsistentlyreleaseandtakeawayatthepacemakerprocess?Whatprocessimprovementwillbenecessaryforthevaluestreamtoflowasyourfuturestatedesignspe