Value stream mapping is used to determinie an ideal-state showing the opportunities for improvement by employing all known lean methods including right-sized tools and value-stream compression. VSM ia a way to raise consciousness of opportunities for improvement. The process starts with grasping the situation by developing a current-state map which follows a product’s path from order to delivery. The map is a straight forward diagram of every step involved in the material and information flows needed to bring a product from order to delivery Next, a futurestate map deploys the opportunities for improvement identified in the current-state map to achieve a higher level of performance at some future point.
Value-stream maps are the blueprints for lean transformations. The value-stream map is a paper-and-pencil representation of every process in the material and information flow of a product or product family, along with key data. It differs significantly from tools such as process mapping or layout diagrams because it includes information flow as well as material flow.
Mapping is a critical initial step in lean transformations because it shows you where you could apply lean techniques, such as kaizen events, for maximum effect. Mapping helps you avoid the common mistake of cherry-picking individual lean techniques, which creates isolated islands of improvement and limited benefits. The mapping cycle of mapping current conditions then quickly drawing and implementing a leaner future state improves the overall flow of value to the customer and delivers the biggest benefits.
This workshop will sharpen your "eyes for waste" and "eyes for flow." Using a manufacturing case study you'll learn how to identify a product family, how to see the entire value stream for a particular product family, how to map the value stream to identify and eliminate waste, what makes a value stream lean, and how to develop a plan to achieve results. Workshop topics include:
Through instruction, discussion, group activities, and hands-on exercises, this workshop will show you how to see value, differentiate value from waste, and eliminate the sources of waste by creating accurate current-state maps and leaner future-state maps for a product family. You'll also develop plans for implementing the future state. At the end of the training, you should be able to:
- Understand and explain to others the benefits of value-stream mapping
- Draw a current-state map
- Identify major lean concepts
- Draw a future-state map
- Develop a basic implementation plan
- Introduction and Getting Started
- The Current State Map Exercise 1
- Determine customer requirements
- Quick walk through to Identify main processes (in order)
- Draw process boxes and fill in information gathered in the walk through
- Indicate where inventory was found
- Determine customer delivery requirements
- Identify what your suppliers are providing
- Find out how your processes know what to make (Information Flow)
- Determine where material is being pushed and where it is being pulled
- Calculate summary metrics - Lead Time/Process Time
- Lean Value Stream
- The Future State Map: Exercise 2
- Takt time?
- Will we build to shipping or to a supermarket?
- Where can we use continuous flow?
- Where do we have to use supermarket pull systems?
- At what single point in the production chain do we trigger production?
- How do we level the production mix at the pacemaker process? (Leveling the mix)
- What increment of work will we release & take away at the pacemaker process? (Leveling the volume)
- What process improvements will be necessary to make the vision reality? (e.g.: uptime, changeover, training)
- Achieving the Future State
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