value stream mapping (current state)

Value Stream MappingValue Stream Mapping

VALUE STREAMVALUE STREAM

All the actions required to bringAll the actions required to bring

a product through its main flows,a product through its main flows,

door-to-door, from raw materialdoor-to-door, from raw material

to the arms of the customer.to the arms of the customer.

VALUE STREAM MAPPINGVALUE STREAM MAPPING

A pencil and paper tool that lets A pencil and paper tool that lets

you SEE and UNDERSTAND the you SEE and UNDERSTAND the

flow of material and information flow of material and information

as a product makes its way as a product makes its way

through the value stream.through the value stream.

• Visualize the entire value stream.Visualize the entire value stream.• Link material + information flows.Link material + information flows.

V.S. MAPPING BENEFITSV.S. MAPPING BENEFITS

PRODUCTION FLOW PRODUCTION FLOW

materialmaterial

informationinformation

• See the sources of waste.See the sources of waste.• Highlight the real decision points.Highlight the real decision points.• Link actions to flow results.Link actions to flow results.• Blueprint your implementation.Blueprint your implementation.• Speak a common language.Speak a common language.

V.S. MAPPING BENEFITSV.S. MAPPING BENEFITS

• Visualize the entire value stream.Visualize the entire value stream.• Link material + information flows.Link material + information flows.

MAPPING THE ‘BIG’ PICTUREMAPPING THE ‘BIG’ PICTURE

seniorseniormgmt.mgmt.

fronfronttlineslines

ELIMINATIONELIMINATIONOF WASTEOF WASTE

VALUE STREAMVALUE STREAMIMPROVEMENTIMPROVEMENT

focusfocus

Value stream improvements driveValue stream improvements drivewaste elimination projects.waste elimination projects.

VALUE STREAM MAPPING STEPSVALUE STREAM MAPPING STEPS

product familyproduct family

current-current-statestate

drawingdrawing future-state future-state

drawingdrawing

work plan work plan





drawingdrawing

work plan work plan


PRODUCT FAMILYPRODUCT FAMILY

A group of products thatA group of products that

passes through commonpasses through common

processing steps and overprocessing steps and over

common equipment in yourcommon equipment in your

downstreamdownstream processes processes..

PRODUCT FAMILY ASPECTSPRODUCT FAMILY ASPECTS

Manufacturing processManufacturing process

How many part numbers How many part numbers

“ “Spin-off” TestSpin-off” Test

PROCESSPROCESS

SPIN-OFF TESTSPIN-OFF TEST Landlocked for future growthLandlocked for future growth Must relocate part of businessMust relocate part of business It must be totally self-sufficientIt must be totally self-sufficient

EquipmentEquipment PersonelPersonel Support activitiesSupport activities

Cannot come back for servicesCannot come back for services Repeat until all product families Repeat until all product families are defined.are defined.

PRODUCT MIX MATRIXPRODUCT MIX MATRIX

AABBCCDDEEFFGG

XXXXXX

XXXX

XXXXXXXXXX

XXXXXXXXXXXXXX

XX

XXXX

XXXXXX

XXXX

XXXXXX

XXXX

XXXXXXXXXX

XXXX

PR

OD

UC

TS

PR

OD

UC

TS

1 2 3 4 5 6 7 81 2 3 4 5 6 7 8

Assembly Steps & EquipmentAssembly Steps & Equipment

MACHINE LOADING ANALYSIS

Part 1 - Pieces per HourPART # DESCRIPTION VOLUME STOCK MACH 1 MACH 2 MACH 3 MACH 4 MACH 5 MACH 6 MACH 7 MACH 8 MACH 9 MACH 10

0000-001 PRODUCT 1 48000 XXXX-01 2610000-002 PRODUCT 2 2500 XXXX-02 125 61 81 1590000-003 PRODUCT 3 2000 XXXX-03 98 139 293 2750000-004 PRODUCT 4 7500 XXXX-04 72 64 107 1840000-005 PRODUCT 5 64000 XXXX-05 95 880000-006 PRODUCT 6 61000 XXXX-06 76 480000-007 PRODUCT 7 7500 XXXX-07 2240000-008 PRODUCT 8 24000 XXXX-08 1930000-009 PRODUCT 9 48000 XXXX-09 73 750000-010 PRODUCT 10 61000 XXXX-10 96 610000-011 PRODUCT 11 48000 XXXX-11 2220000-012 PRODUCT 12 24000 XXXX-12 1360000-013 PRODUCT 13 64000 XXXX-13 2360000-014 PRODUCT 14 55000 XXXX-14 2350000-015 PRODUCT 15 48000 XXXX-15 2220000-016 PRODUCT 16 48000 XXXX-16 1360000-017 PRODUCT 17 48000 XXXX-17 237 2000000-018 PRODUCT 18 55000 XXXX-18 90 930000-019 PRODUCT 19 55000 XXXX-19 292 1860000-020 PRODUCT 20 64000 XXXX-20 254 333

834500

Part 2 - Annual Hours per MachinePART # DESCRIPTION VOLUME STOCK MACH 1 MACH 2 MACH 3 MACH 4 MACH 5 MACH 6 MACH 7 MACH 8 MACH 9 MACH 10

0000-001 PRODUCT 1 48000 XXXX-01 184 0 0 0 0 0 0 0 0 00000-002 PRODUCT 2 2500 XXXX-02 20 41 31 16 0 0 0 0 0 00000-003 PRODUCT 3 2000 XXXX-03 20 14 7 7 0 0 0 0 0 00000-004 PRODUCT 4 7500 XXXX-04 104 117 70 41 0 0 0 0 0 00000-005 PRODUCT 5 64000 XXXX-05 674 727 0 0 0 0 0 0 0 00000-006 PRODUCT 6 61000 XXXX-06 803 1271 0 0 0 0 0 0 0 00000-007 PRODUCT 7 7500 XXXX-07 33 0 0 0 0 0 0 0 0 00000-008 PRODUCT 8 24000 XXXX-08 124 0 0 0 0 0 0 0 0 00000-009 PRODUCT 9 48000 XXXX-09 0 0 0 0 658 640 0 0 0 00000-010 PRODUCT 10 61000 XXXX-10 0 0 0 0 635 1000 0 0 0 00000-011 PRODUCT 11 48000 XXXX-11 0 0 0 0 216 0 0 0 0 00000-012 PRODUCT 12 24000 XXXX-12 0 0 0 0 176 0 0 0 0 00000-013 PRODUCT 13 64000 XXXX-13 0 0 0 0 271 0 0 0 0 00000-014 PRODUCT 14 55000 XXXX-14 0 0 0 0 234 0 0 0 0 00000-015 PRODUCT 15 48000 XXXX-15 0 0 0 0 216 0 0 0 0 00000-016 PRODUCT 16 48000 XXXX-16 0 0 0 0 353 0 0 0 0 00000-017 PRODUCT 17 48000 XXXX-17 0 0 0 0 203 0 240 0 0 00000-018 PRODUCT 18 55000 XXXX-18 0 0 0 0 611 0 591 0 0 00000-019 PRODUCT 19 55000 XXXX-19 0 0 0 0 188 0 296 0 0 00000-020 PRODUCT 20 64000 XXXX-20 0 0 0 0 252 0 0 192 0 0

834500 1963 2171 108 64 4014 1640 1127 192 0 0

PRODUCT FAMILY ASPECTSPRODUCT FAMILY ASPECTS

“ “Spin-off” TestSpin-off” Test

Manufacturing processManufacturing process

How many part numbersHow many part numbers

Customer names Customer names

Customer volumesCustomer volumes

Delivery frequencyDelivery frequency

PROCESSPROCESS

CUSTOMERCUSTOMER

CUSTOMER REQUIREMENTSCUSTOMER REQUIREMENTS

Customer Volume Part #s Ship Freq. PackageCustomer Volume Part #s Ship Freq. Package

AcmeAcme

PinnaclePinnacle

VertexVertex

CrownCrown

3000/wk3000/wk

1500/wk1500/wk

1000/wk1000/wk

500/wk500/wk

44

22

22

22

DailyDaily

DailyDaily

WeeklyWeekly

MonthlyMonthly

10/box10/box

10/box10/box

10/box10/box

10/box10/box

Product Family:Product Family: Tilt Mechanisms Tilt Mechanisms





drawingdrawing

work plan work plan


drawingdrawing

START-UP MAPPING TIPSSTART-UP MAPPING TIPS

1.1. One person does the entire map. One person does the entire map.22. Start at the customer end.. Start at the customer end.3.3. Walk the actual pathways of both Walk the actual pathways of both

material and information flow.material and information flow.4.4. Do a quick walk-through first. Do a quick walk-through first.5.5. Do a detailed walk-through, using Do a detailed walk-through, using

a stop watch to collect actuala stop watch to collect actualtimes and counting inventory.times and counting inventory.

6.6. Draw by hand in pencil. Draw by hand in pencil.

WHY IN PENCIL, BY HAND?WHY IN PENCIL, BY HAND?

No delays

You do it, youunderstand it Focus on flow,

not a computer

Fixing your ownmistakes fine-tunes skills

MAP LAYOUT GEOGRAPHYMAP LAYOUT GEOGRAPHY

1111

1717

CustomerInfo.

Process Flow Information

SupplierInfo.

Production ControlInfo.

Time Line

START WITH THE CUSTOMERSTART WITH THE CUSTOMERCustomer Requirements:Customer Requirements:• State Street Assembly Co.State Street Assembly Co.• 18,400 pieces per month18,400 pieces per month

- 12,000 Type LH- 12,000 Type LH- 6,400 Type RH- 6,400 Type RH

• 20 units per tray 20 units per tray • Operates on two shiftsOperates on two shifts• 1 truck per day1 truck per day

State StreetAssembly

18,400 pcs/mo

- 12,000 LH- 6,400 RH

Tray = 20 pcs2 shifts

Icons:Icons:

CURRENT STATE MAPCURRENT STATE MAP


18,400 pcs/mo

- 12,000 LH- 6,400 RH


COLLECTING PROCESS DATACOLLECTING PROCESS DATA Number of product variations (P/N’s)Number of product variations (P/N’s) Machine(s) usedMachine(s) used C/T (cycle time)C/T (cycle time) C/O (changeover time)C/O (changeover time) Uptime (on-demand machine time)Uptime (on-demand machine time) EPE (production sequence time)EPE (production sequence time) Number of operatorsNumber of operators Pack sizePack size Working time (minus breaks)Working time (minus breaks) Scrap rateScrap rate

200 T200 TPresPresss

Weld IIWeld II Weld IWeld I

Assembly IAssembly I Assembly IIAssembly II

WeldingWeldingInspectionInspection

AreaArea

PRESS DEPT.PRESS DEPT.

WELDING DEPT.WELDING DEPT.

SHIPPINGSHIPPING

ASSEMBLY DEPT.ASSEMBLY DEPT.

Steel CoilSteel CoilStorageStorage

Stamped PartsStamped PartsStorageStorage

FinishedFinishedGoodsGoodsStorageStorage

ACME STAMPING FACTORY LAYOUTACME STAMPING FACTORY LAYOUT

= WIP in Baskets= WIP in Baskets = Finished Goods in Trays= Finished Goods in Trays

Welded Parts Welded Parts StorageStorage

FINALFINALIINNSSPPEECCTTIIOONN

ACME STAMPING MATERIAL FLOWACME STAMPING MATERIAL FLOW

1. Stamping1. Stamping

2. Spot-welding Workstation #12. Spot-welding Workstation #1

3. Spot-welding Workstation #23. Spot-welding Workstation #2

4. Assembly Workstation #14. Assembly Workstation #1

5. Assembly Workstation #25. Assembly Workstation #2

6. Shipping6. Shipping

Where should we start?Where should we start?

1xDaily

1xDaily

SHIPPING

Staging

I2700 L2700 L1440 R1440 R

I

ACME STAMPING PROCESSACME STAMPING PROCESS

ShippingShipping::• 1 truck per day1 truck per day• 20 pieces/tray20 pieces/tray• 10 trays/pallet10 trays/pallet• 30 “L” pallets/day30 “L” pallets/day• 16 “R” pallets/day16 “R” pallets/day• Inventory:Inventory: - 2700 L- 2700 L - 1440 R- 1440 R



18,400 pcs/mo

- 12,000 LH- 6,400 RH


SHIPPINGI

2700 L1440 R

Staging

1xDaily

Assembly #2Assembly #2• 2 part numbers2 part numbers• 1 operator1 operator• 2 shifts2 shifts• No setupsNo setups• 40 sec. cycle time40 sec. cycle time• 100% uptime100% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 1200 LH- 1200 LH - 640 RH- 640 RH

ACME STAMPING PROCESSACME STAMPING PROCESSIcons:Icons:

ASSEMBLY #2

1

C/T = 40 secondsC/O = 0

Uptime = 100%2 Shifts

27,600 sec/shift

I1200 L1200 L 640 R640 R

I



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

I1200 L 640 R

I2700 L1440 R

Staging

Assembly #1Assembly #1• 2 part numbers2 part numbers• 1 operator1 operator• 2 shifts2 shifts• No setupsNo setups• 62 sec. cycle time62 sec. cycle time• 100% uptime100% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 1600 LH- 1600 LH - 850 RH- 850 RH


ASSEMBLY #1

1



27,600 sec/shift

I1600 L1600 L 850 R850 R

I



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

ASSEMBLY #1

1



27,600 sec/shift

I1600 L 850 R

I1200 L 640 R

I2700 L1440 R

Staging

Spot Weld #2Spot Weld #2::• 2 part numbers2 part numbers• 1 operator1 operator• 2 shifts2 shifts• 10 min. setup10 min. setup• 46 sec. cycle time46 sec. cycle time• 80% uptime80% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 1100 LH- 1100 LH - 600 RH- 600 RH


S.WELD #2

1

C/T = 46 seconds

C/O = 10 min.Uptime = 80%

2 Shifts27,600 sec/shift

I1100 L1100 L 600 R600 R

I



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

ASSEMBLY #1

1



27,600 sec/shift

S. WELD #2

1

C/T = 46 secondsC/O = 10 minutes


27,600 sec/shift

I1100 L 600 R

I1600 L 850 R

I1200 L 640 R

I2700 L1440 R

Staging

Spot Weld #1Spot Weld #1::• 2 part numbers2 part numbers• 1 operator1 operator• 2 shifts2 shifts• 10 min. setup10 min. setup• 39 sec. cycle time39 sec. cycle time• 100% uptime100% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 4600 LH- 4600 LH - 2400 RH- 2400 RH


S.WELD #1

1

C/T = 39 seconds

C/O = 10 min.Uptime = 100%

2 Shifts27,600 sec/shift

I4600 L4600 L2400 R2400 R

I



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

ASSEMBLY #1

1



27,600 sec/shift

S. WELD #2

1



27,600 sec/shift

S. WELD #1

4600 L2400 R 1



27,600 sec/shift

I I1100 L 600 R

I1600 L 850 R

I1200 L 640 R

I2700 L1440 R

Staging

StampingStamping::• 200 Ton Press200 Ton Press• Auto. Coil FeedAuto. Coil Feed• Run every 2 wks.Run every 2 wks.• 1 hour setup1 hour setup• 1 sec. cycle time1 sec. cycle time• 85% uptime85% uptime• 2 - 10 min. breaks2 - 10 min. breaks• Inventory:Inventory: - 5 days of Coils- 5 days of Coils


STAMPING

C/T = 1 secondC/O = 1 hour

Uptime = 85%EPE = 2 weeks27,600 sec/shift

ICoilsCoils

5 days5 days200 T



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

ASSEMBLY #1

1



27,600 sec/shift

S. WELD #2

1



27,600 sec/shift

S. WELD #1

1



27,600 sec/shift

I1100 L 600 R

I1600 L 850 R

I1200 L 640 R

I2700 L1440 R

Staging4600 L2400 R

STAMPINGI

Coils5 days

C/T = 1 secondsC/O = 1 hour

Uptime = 85%27,600 sec./shiftEPE = 2 weeks

I200 T

STAMPING

ADD THE SUPPLIER(S)ADD THE SUPPLIER(S)

Michigan Steel CoMichigan Steel Co::

• 1 truck Tuesday1 truck Tuesday

• 1 truck Thursday1 truck Thursday

• 500 foot coils500 foot coils Tues. +Thurs

MichiganSteel Co.

500 ft. coils



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

ASSEMBLY #1

1



27,600 sec/shift

S. WELD #2

1



27,600 sec/shift

S. WELD #1

4600 L2400 R 1



27,600 sec/shift

STAMPINGI

Coils5 days


Uptime = 85%27,600 sec./shift

EPE = 2 weks

I I1100 L 600 R

I1600 L 850 R

I1200 L 640 R

I2700 L1440 R

Staging200 T

MichiganSteel Co.

500 ft. coils

Tues. +Thurs.

This is theMaterial Flow

INDoor

Door to Door Value Stream

OUTDoor

Acme Production ControlAcme Production Control::• 30/60/90 day forecasts30/60/90 day forecasts from customerfrom customer• 6 week forecast to supplier6 week forecast to supplier• Weekly supplier releasesWeekly supplier releases• Daily firm order from theDaily firm order from the customercustomer• Weekly MRP generationWeekly MRP generation• Weekly build schedules toWeekly build schedules to internal operationsinternal operations• Daily shipping scheduleDaily shipping schedule

ADD INFORMATION FLOWADD INFORMATION FLOWIcons:Icons:

PRODUCTIONCONTROL

MRP

DailyOrder

WeeklySchedule



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

ASSEMBLY #1

1



27,600 sec/shift

S. WELD #2

1



27,600 sec/shift

S. WELD #1

4600 L2400 R 1



27,600 sec/shift

STAMPINGI

Coils5 days



I I1100 L 600 R

I1600 L 850 R

I1200 L 640 R

I2700 L1440 R

Staging200 T

MichiganSteel Co.

500 ft. coils

Tues. +Thurs.

PRODUCTIONCONTROL

MRPDailyOrder

30/60/90 dayForecasts

WeeklyRelease

6-weekForecasts

Weekly Schedule

Daily ShipSchedule

ADD THE TIME LINEADD THE TIME LINE

• Process leadtime is usually the CycleProcess leadtime is usually the Cycle Times (Value Added Time) for all ofTimes (Value Added Time) for all of the operations in the process.the operations in the process.

• Inventory leadtime is the time it takesInventory leadtime is the time it takes to work through the queues of stockto work through the queues of stock throughout the Value Stream.throughout the Value Stream.

Inventory Days =Inventory Days = Amount on HandAmount on Hand

Daily Customer NeedDaily Customer Need



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

ASSEMBLY #1

1



27,600 sec/shift

S. WELD #2

1



27,600 sec/shift

S. WELD #1

4600 L2400 R 1



27,600 sec/shift

STAMPINGI

Coils5 days



I I1100 L 600 R

I1600 L 850 R

I1200 L 640 R

I2700 L1440 R

Staging200 T

MichiganSteel Co.

500 ft. coils

Tues. +Thurs.

PRODUCTIONCONTROL

MRPDailyOrder


WeeklyRelease

6-weekForecasts

Weekly Schedule

Daily ShipSchedule

1 second 39 sec. 62 sec. 40 sec. ValueAddedTime

= 188 sec.46 sec.

5 days 7.6 days 1.8 days

2.7 days

2 days 4.5 days

ProductionLeadtime

23.6days=

IDENTIFY OPPORTUNITIESIDENTIFY OPPORTUNITIES

• The Current State Map shows what is The Current State Map shows what is happening “right now.”happening “right now.”

• It identifies wasteful steps and slow-down It identifies wasteful steps and slow-down causes.causes.

• It helps visualize how operations can be It helps visualize how operations can be combined to “flow” production.combined to “flow” production.

• It lets you see where “pull” systems make It lets you see where “pull” systems make sense when the product can’t flow.sense when the product can’t flow.

• It shows how the improvements impact the It shows how the improvements impact the value streamvalue stream..



18,400 pcs/mo

- 12,000 LH- 6,400 RH


1xDaily

SHIPPINGASSEMBLY #2

1



27,600 sec/shift

ASSEMBLY #1

1



27,600 sec/shift

S. WELD #2

1



27,600 sec/shift

S. WELD #1

4600 L2400 R 1



27,600 sec/shift

STAMPINGI

Coils5 days



I I1100 L 600 R

I1600 L 850 R

I1200 L 640 R

I2700 L1440 R

Staging200 T

MichiganSteel Co.

500 ft. coils

Tues. +Thurs.

PRODUCTIONCONTROL

MRPDailyOrder


WeeklyRelease

6-weekForecasts

Weekly Schedule

Daily ShipSchedule

1 second 39 sec. 62 sec. 40 sec. ValueAddedTime

= 188 sec.46 sec.

5 days 7.6 days 1.8 days

2.7 days

2 days 4.5 days

ProductionLeadtime

23.6days=

“flow” cell pullpullpull

TWI CASE STUDYTWI CASE STUDY

• Read through the TWI Case Study Read through the TWI Case Study hand out information.hand out information.

• Draw a Current State Map, using the Draw a Current State Map, using the tools and techniques described in tools and techniques described in this section.this section.

• Return to class prepared to discuss Return to class prepared to discuss your map and why you drew it that your map and why you drew it that way.way.

C/T = oper 10 sec mach 30 secC/O = 15 min - 1

hrUptime 90%

TWI CURRENT STATE MAP

OE + AftermarketCustomers

24,000 pcs/mo240 P/N’s

25-200 pc ordersBox = 5 pcs

VariousDaily

SHIPPINGASSEMBLY

6

C/T = 195 sec total

C/O = 10 minUptime = 100%

3 end fittings6 combos/rod

DEFLASH

1

WELD #2

1

WELD #1

5 days

1

MACHINING

IForgings20 days

I I3 days

I3 days

I6 days

I4 days Staging

2xMonthly

Orders60 days out

Orders

Daily Priorities

Daily ShipSchedule

30 sec. 30 sec.

2 days

30 sec.

20 days 5 days 3 days 3 days 5 days 6 days

Outside Painter

I5 days

Daily

Daily

MichiganSteel Co.

CUTI

Rods20 days

C/T = 15 secondsC/O = 15-60 min.Uptime = 100%

1

4 days


hrUptime 80%


hrUptime 100%

LT =48 days

I 2 days

IndiannaCastings

Forgings12 week LT

Rods16 week LT

Orders

ShopOrders To Weld Area

Supervisor

PRODUCTIONCONTROL

195 sec.

4 days

I

Size Change2 weeks out

C/T = 30 seconds2

pieces/assemblyC/O = 2 hoursUptime = 85%

60 sec. VA =345 sec

value stream mapping (current state)

Engineering

product familiesrepeat

product familyproduct

entire value stream

description volume stock

link material

mapping benefitsv

information flows

link actions