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  • Slide 1
  • The Lean Enterprise Value Stream Mapping Lean Foundations Continuous Improvement Training Lean Foundations Continuous Improvement Training
  • Slide 2
  • The purpose of this module is to present the foundational principles of Waste Identification and elimination. Learn the History and Purpose of Value Stream Mapping. Learning Objectives Learning Objectives
  • Slide 3
  • Short History Origins in Toyota, circa1955 The way of doing business Also called Material and Information Flow Mapping Used by Toyota Motors to show both current and ideal states as part of the lean implementation process Discussed in Lean Thinking Further developed and documented by the Lean Enterprise Institute of Brookline, Mass. Learning to See 1996 1998
  • Slide 4
  • What is the Value Stream? Total Value Stream SUPPLIERSYOUR PLANT OR BUSINESSCUSTOMER TO END USER All the actions, both value added and non-value added, currently required to bring a product from raw materials to the customer.
  • Slide 5
  • The Value Stream Perspective A value stream is all the actions (both value added and non-value added) currently required to bring a product (or transaction) though the main flows essential for every product/ service: from raw material/ (customer need), through all the required steps, then back to the arms of the customer. Taking a value stream perspective means working on the big picture, not just individual processes, and improving the whole, not just optimizing the parts. TOTAL VALUE STREAM SUPPLY PARTNERS YOUR PLANT OF COMPANYCUSTOMER TO END USER
  • Slide 6
  • Value Stream Mapping Lets look at an EXAMPLE
  • Slide 7
  • 7 WIP 870 QTIME 72H MELT 903M INSP CHEM Hold Furnace Cast 903 INSP PROFILE WIP 696 QTIME P/T 6N LOT 75K P/T 8H WIP 8 COILS 120K P/T 3 HR 15K WIP STORESTAGE BREAKDOWN 911 RECSTAGE LEAD 2231.1 VA 210.1 7% SCRAP WIP 746K QTIME 8 1OK LOT 1 COIL TIME.1 WIP 15K WIP 108K 8HR Q/T 8 DOWNTIME 15% DOWNTIME 15.5% 8683 Value Stream Map Operational example 1. Map major process steps 2. I.D. Value (green/ yellow) / Non-value (red) 3. Capture all times, quantities 4. Prioritize areas to improve X SHIPPED PER DAY 850K 1.870 WIP BEING WORKED 4.276 WIP BEING STORED
  • Slide 8
  • Customer MACHINING C/T=1568 m C/O=50 min. 2 SHIFTS OPER. 48 Daily FIFO Prodn Cont. Supplier Orders IRREGULAR ASSEMBLY C/T=936 m C/O=0 min. 1 SHIFT OPER. 24 TEST C/T=60 m C/O=30 min. 1 SHIFTS OPER. 5 FINISH C/T=210 m C/O=0 min. 1 SHIFTS OPER. 6 DISPATCH C/T=30 m C/O=0 min. 1 SHIFTS OPER. 2 FIFO OXOX 1 DAY 2 DAYS 900 MINS 240 MINS150 MINS120 MINS 1568 MINS936 MINS60 MINS210 MINS30 MINS 4 WEEKS OUT 12 WEEK FORECAST < 1/2 DAY

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