Value Stream Mapping is a Lean technique used to analyze the
current material and information flow necessary to bring out the products or
provide services for the customer. This technique includes all the activities
that follow the product from the customer order, going through the entire
production process and the finally delivery to the customer.
Value Stream Mapping is the perfect argument for Lean
practitioners to show where data comes into play, how it is collected quickly
and efficiently, and how Lean project action plans are created from this data.
Because anywhere is a process there is also waste, it is our concern to find
the best solutions and techniques to reduce it or even eliminate waste at all.
The advantage of using this method allows anybody to see
both process flow and communications flow within the process or value stream.
Because of this ability to gather, analyze and present information in short
period of time, this method has rapidly gained popularity in the process of
continuous improvement. The most important goal of Value Stream Mapping method
is that identifies opportunities for improvement for future periods of time.
We can use VSM as a Lean method to identify the
opportunities of improvements for future Periods of time.
VSM method is also associated with production activity,
being used for:
- Efficiency of production activities;
- Logistics activities;
- supplying activities;
- Software development;
- developing new products;
- Industrial activities related.
Because the VSM is an analytical method, and is based on
details, depending on the level of details, the VSM can address only to a
process step, to one or the production lines, or to the entire factory.
Current State Mapping
To describe clearly the company situation at the present
time and for the future, the easiest method is by using VSM as a graphic
instrument representation.
For the Current State Map this principle is based on:
- Observing the process of making a
particular product or providing a service
- Recording specific data
(performed operations, inputs, outputs,
Performance indicators, parameters
of work, workplace organization, other
Necessary information)
- Representation of all the results
of these observations using the specific
Graphic symbols.
Future State Mapping
The Future State Map can be shaped to guide the positive
changes that are desired for the future. The future state map includes
essential actions to continuously improve the project. Lean practitioners can
rely on this map because it is a process in which action plans can be created
by the mapping team. Future state mapping is a completely relay on the
company’s mission and improvement which are needed in certain areas.
Future State Map is the starting point for a good plan of
improvement in certain area. It also provides a solution in decision making and
to examine the capacity of workmanship in improving shop floor from current
stat map. Hence future state map place a major role in VSM (Value Stream
Mapping).
Symbols used in Value Stream Mapping (VSM)
The following are the standard symbol used in Value Stream
Mapping (VSM)
1. Material flow icons
2. Inventory icons
3.Push/finished good flow icons
4. FIFO icons
5. Information flow icons
Steps involved in Value Stream Mapping (VSM)
When the project team starts to draw the Valve stream map it
is better to have some guiding steps to make sure that the team include all the
required information.
ü
The map should include all actions (both value
added and non-value added) currently required to make the product to cover the
main processes.
ü
Usually, use a pencil and paper to draw the
Value Stream Map. The next step refers to the analysis of current state,
finding solutions to improve the current state map, to prepare and implement an
action plan for improvement (with deadlines, responsibilities, required
resources and clear targets).
ü
The time which adds value is important compared
to the total time needed to achieve the product or providing a service, from
customer order until delivery.
ü
It is usually necessary to work in a
multifunctional team to understand and draw the observed situation.
ü
Value Stream Maps are drawn as pictures of the
process and used to document both Current State Map (reality) and the Future
State Map (the goal).
ü
The Current State Map is the baseline view of
the existing process from which all improvements are measured.
ü
The Future State Map represents the vision of
how the project team sees the value stream at a point in the future after
improvements have been made
Example for Value Stream Mapping (VSM)
The below picture shows the current state of production
system
In which a monthly production in a shift= 80405
pieces and b shift=10256 pieces
Daily production a shift= 3833 pieces and b
shift=488 pieces
Factory runs for 2 Shifts/day=960 mins
The following steps are followed to draw current state
mapping
1 Draw
customer, supplier and production control icons.
2. Enter
customer requirements per month and per day.
3. Calculate
daily and/or monthly production.
4. Draw
outbound shipping icon and truck with delivery frequency.
5. Draw
inbound shipping icon, truck and delivery frequency.
6. Add
process boxes in sequence, left to right.
7. Add data
boxes below.
8. Add
communication arrows and note methods and frequencies.
9. Obtain
process attributes and add to data boxes. Observe all times directly!
10. Add
operator symbols and numbers.
11. Add
inventory locations and levels in days of demand and graph at bottom.
12. Add
push, pull and FIFO icons.
13. Add
other information that may prove useful.
14. Add
working hours.
15. Cycle
and Lead Times.
16.
Calculate Total Cycle Time and Lead Time.
Current state mapping is plotted. It should thoroughly study to find out
the points for improvement such as to reduce cycle time, to reduce non-value
added activities, to reduce inspection time ,uneven movement of operators,
reduce inventory activity .Once the changes are pointed out and it can be made
a positive change that are designed for the future state mapping.
Post a Comment