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Lean-Insight.comLean Six Sigma Training
Part 4
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Drawing a Current State Map
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Drawing a Current State Map
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Drawing a Current State Map
Collect information while walking the actual paths of material and information yourself.
Walk the path once to get a feel of the flow and sequence of processes, then go back and start collecting information.
Begin at the end. Start closest to the customer and you will focus on things linked most closely to the customer.
Bring a stopwatch, see it and time it for yourself do not trust information from the “system”.
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Lean and the Value Stream
• All of the actions (both value added and non-value added) required to bring a product or service through from process initiation to the customer
• Especially useful in Knowledge Flow processes where waste is difficult to see
• Identifies value add and non value add activities and time
• Useful in developing a prioritized roadmap for improvement plans
I IOrder Entry Proposal Confirmation
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Order Entry Process – Value Stream Map
Customer
Receive Order Write Down Order
Part# Lookup Plant Order Review
Contact Customer
Enter Order
III50
= 24 III125
III55
III60
III35
= 24 = 24 = 4 = 24 = 5
DOR = 25”Resources = 24Quality = 50%
DOR = 120”Resources = 24Quality = 98%
N/AResources = 24Quality = 90%
DOR = 600”Resources = 4Quality = 95%
DOR = 200”Resources = 24Quality = 95%
DOR = 60”Resources = 4Quality = 92%
III75
34 Min.
20 Secs
23 Min. 57 Min. 25 Min. 27 Min. 16 Min.
21 Secs 25 Secs 600 Secs 19 Secs 22 Secs
LeadTime
Proc.Time
= 182 Min
= 12 Min.
TAKT Time27,000 sec990 lines = 27.3 sec=
Daily Orders (fax/phone)
Request Status (fax/phone/email)
CS OrderMgmtSystem
Plant Order Mgmt System
CS Order Mgmt System
19,800 lines/Mo
MRP
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Prioritize Improvement Opportunities
Prod’n Cont.
Suppliers
OPSI
CRC
Prod’n Cont.
HLAGEC WeeklyOrders
4 WEEKFORECAST
MRPDailyOrders
13 WEEKFORECAST
Customer
Forecast
Orders
Sales13 WEEK FORECAST
Daily
SHIP
30 Min. 1020 Min. 25 Min. 30 Min.
DailySchedule
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TEST CONFASSY
10 Days 10 Days 5 Days
6 4 2
Ass’y WIP210 Units$513,0003 Days Worth
Brds + RIP$3,300,00019 Days Worth
Test WIP+FG$1,700,00010 Days Worth
8 Days
Raw Bds 8 WKS
SMT
3
15 Min.
7 Days
42 Min.
3.5 Days
HA TEST
2 2
24 Min.
3 Bd. Assy.2,360 Units$425,00011 Days Worth
Non-Value Add 1,020 Hrs. (98% of Time)
Value Add 20 Hrs. (2% of Time)
I nformationMaterial
Flow:I nformationMaterial
Flow:
LongSet Ups
SMED
Too MuchInventory
Create Supermarket
Too MuchVariation
Heijunka
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3. Flow
• Movement of products, services and knowledge down the value stream•Objective is continuous flow as product, service and knowledge is transformed by continuously adding value•Flow created by eliminating Queue’s and Stops
Which would yourcustomers liketo experience?
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Cross Training
Cross training is key to a lean workplace. As you are developing a standard operations routine, evaluate whether all
operators can do all jobs required. Develop a cross training plan with the team to close any gaps that exist.
1. Cross training allows for worker flexibility, and reduces fatigue due to doing the same thing over and over.
2. Perhaps most importantly, workers gain knowledge of the upstream and downstream parts of their process flow. This helps generate more improvement ideas.
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Lean-Insight.com
If you are looking for Lean + Six Sigma training Course along with certification in Bangalore visit: http://lean-insight.com/six-sigma-training-bangalore/
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