Lean Manufacturing Module 2

8/11/2019 Lean Manufacturing Module 2

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LEANMANUFACTURING

Module-2

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POM04


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Value Stream Mapping

A very powerful tool for implementing the lean

transformation process is Value Stream Mapping (VSM).

Value stream mapping is a pencil and paper tool that

helps you to see and understand the flow of material and

information as a product makes its way through the value

stream.

A value stream is all the actions (both value added and

non-value added) currently required to bring a product

through the main flows essential to every product.

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Value Stream Mapping

Current State Map

Follow a productsproduction path from customer to supplier,

and carefully draw a visual representation of every process in

the material and information flow.

Future State Map

Ask a set of key questions and draw the map of how value

should flow in the future (desired flow).

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Value Stream Mapping4


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Value Stream Mapping5

Steps

Select one value stream - a product family

Walk the physical flow of materialno data collection

Walk the flow again, collecting dataDraw the Current State Map

Identify opportunities to eliminate waste and create flow

Draw the Future State Map

Generate a Value Stream Plan

Start making the improvements

Conduct Value Stream Reviews

Repeat the cycle


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Value Stream Mapping Icons7


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Terms one should know before

mapping10

Customer Need

Demand : Number of units per day the customer wants.

Available Working Time: Scheduled working time minus breaks,meeting and clean up time

Inventory

WIP : Number of units waiting to be worked on or waiting to bemoved.

Finished: Number of units in stores or waiting to be shipped .


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mapping11

Each Process StepCycle Time : The time between one part coming off the process

and the next part coming off.

Number of people: Required to operate the process

Uptime: The percentage of time the equipment is available to run

,when it is needed to run

Batch Size: Typical lot size or minimum.

Change Over Time: The time from the last good piece of one

batch to the first good piece of the next batch.

EPE..Every part every ____ .How often do you changeover toroduce this art.


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mapping12

Each Process Step

Takt TimeTT : Available time per day/demand per day.

Inventory(Measured in days) = Number of units /demandper day

Overall Flow

Process Lead Time : The time for a unit to make all the way through theprocess (Sum of Inventory days + Sum of Cycle times).

Processing Time: The time actually spent performing work on the unit

(Sum of Cycle times)


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ACME STAMPING CASESTUDY


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Whats wrong with Acmes Value

Stream?20

Traditional mass production thinking about economies of

scale

Batches pushed through = Waste

Look at VA time compared to time in plant

Documents

Lean Manufacturing Module 2