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Value Stream Mapping Process What, Where, When, Why, Who, Which, How etc  Anand Subramaniam
Be aware..  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Highlights ,[object Object],[object Object],[object Object],[object Object],[object Object]
Highlights - 1 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
What is a Lean Process ? Define value  from the  customer’s  perspective Map the value stream Create flow;  eliminate the root causes of waste Create pull where flow is difficult to achieve Seek perfection via continuous improvement
VSM – Why, What, Where? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Value Add & Non Value Add ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
VSM - Principles  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
SIPOC - Process Map S I O C P S uppliers I nputs P rocess O utputs C ustomers
Definition ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Highlights - 2 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Current Process Challenges ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Conceptual Overview - Where to start? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Current state drawing Future state drawing Work plan & implementation Charter / Scope Product family
VSM Charter ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
VSM - Boundary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Define Boundary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Eg. Boundary - Start & End Points ,[object Object],[object Object],[object Object],[object Object],Define Go-to Market Drivers Review Objectives, Goals & Strategies Identify Risks, Assumption & Constraints Conduct “What If” Scenarios START Evaluate Scenarios Approve Go-to Market Plan ,[object Object],[object Object],[object Object],[object Object],END
Material & Information Flow ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Resource Identification  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Product Family Matrix X X X X X U X X X X X X XX X X X X X EL X X X X X L X X X X X X M X X X X X X S X X X X X X ES P R O D U C T S 8 7 6 5 4 3 2 1 Routing - Process / Operations #
Data Collection ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Future State Questions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Design Future State – Blueprint ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Highlights - 3 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Define Customer’s Demand ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Map Basic Production Process ,[object Object],[object Object],[object Object],[object Object],[object Object]
Map Process (Contd.) – Mapping Icons © 2007 Pearson Education
Define Data To Be Collected ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Define Data (Contd.) - Work Time Calculation ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Collect & Map Data (Customer & Supplier)
Map Information Flow
Calculate Current State ,[object Object],[object Object],[object Object],Press Process Type L + S = 2,250 pieces (1,000 + 1,250)  Duration  = 3.5 days (2,250/640)
Result - Current State © 2007 Pearson Education A Representative Current State Map for a Family of Retainers at a Bearings Manufacturing Company
Compute Takt Time ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Total - Processing / Work Time 60 Seconds
Line Balancing Work or Process Time = 60 Sec Takt Time = 39 Sec  Work / Takt time = # of Operators Required = 60/39 = 1.54
Line Balancing (Contd.) ,[object Object],[object Object],[object Object]
Line Balancing (Contd.)
Highlights - 4 ,[object Object],[object Object],[object Object]
Future State (To~Be) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Implementation Road Map ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Improvement Results Morale # steps CT/LT ratio Cycle time Lead time % Improvement Future State Current State Metric
Highlights - 5 ,[object Object]
Excellence Road Map Approach  /  Develop Plan Deployment  /  Execute Plan Results 1 Assess  &  understand Set direction Develop key  plans 2 3 Communicate  &  integrate  plans 4 Develop cross - functional  strategy teams 5 Develop  /  Integrate  detailed  implementation  plans 6 Execute  implementation  plans 7 Quarterly ,  integrated  operations  leadership  review 8 Strategic Planning Process 1 Define the  process Establish  metrics Determine  performance 2 3 Analyse  process  stability 4 Set goals 5 Analyse  &  plan  improvements 6 Implement  improvement 7 Process Based Management Update Future  State Set initiative  priorities Initiative  # 1 Initiative  # 2 Initiative  # 3 Initiative  # 4
[object Object],[object Object]

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Value Stream Mapping Process

  • 1. Value Stream Mapping Process What, Where, When, Why, Who, Which, How etc Anand Subramaniam
  • 2.
  • 3.
  • 4.
  • 5. What is a Lean Process ? Define value from the customer’s perspective Map the value stream Create flow; eliminate the root causes of waste Create pull where flow is difficult to achieve Seek perfection via continuous improvement
  • 6.
  • 7.
  • 8.
  • 9. SIPOC - Process Map S I O C P S uppliers I nputs P rocess O utputs C ustomers
  • 10.
  • 11.
  • 12.
  • 13.
  • 14.
  • 15.
  • 16.
  • 17.
  • 18.
  • 19.
  • 20. Product Family Matrix X X X X X U X X X X X X XX X X X X X EL X X X X X L X X X X X X M X X X X X X S X X X X X X ES P R O D U C T S 8 7 6 5 4 3 2 1 Routing - Process / Operations #
  • 21.
  • 22.
  • 23.
  • 24.
  • 25.
  • 26.
  • 27. Map Process (Contd.) – Mapping Icons © 2007 Pearson Education
  • 28.
  • 29.
  • 30. Collect & Map Data (Customer & Supplier)
  • 32.
  • 33. Result - Current State © 2007 Pearson Education A Representative Current State Map for a Family of Retainers at a Bearings Manufacturing Company
  • 34.
  • 35. Total - Processing / Work Time 60 Seconds
  • 36. Line Balancing Work or Process Time = 60 Sec Takt Time = 39 Sec Work / Takt time = # of Operators Required = 60/39 = 1.54
  • 37.
  • 39.
  • 40.
  • 41.
  • 42. Improvement Results Morale # steps CT/LT ratio Cycle time Lead time % Improvement Future State Current State Metric
  • 43.
  • 44. Excellence Road Map Approach / Develop Plan Deployment / Execute Plan Results 1 Assess & understand Set direction Develop key plans 2 3 Communicate & integrate plans 4 Develop cross - functional strategy teams 5 Develop / Integrate detailed implementation plans 6 Execute implementation plans 7 Quarterly , integrated operations leadership review 8 Strategic Planning Process 1 Define the process Establish metrics Determine performance 2 3 Analyse process stability 4 Set goals 5 Analyse & plan improvements 6 Implement improvement 7 Process Based Management Update Future State Set initiative priorities Initiative # 1 Initiative # 2 Initiative # 3 Initiative # 4
  • 45.