1

Lean-Insight.comLean Six Sigma Training

Part 4

2

Drawing a Current State Map

3

Drawing a Current State Map

4

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”.

5

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

6

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

7

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

6

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

8

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?

9

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.

10

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/