Value Stream Mapping Process - Why, Who, What, When, Where, How etc etc

1. Value Stream Mapping Process What, Where, When, Why, Who, Which, How etc Anand Subramaniam

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

9. SIPOC - Process Map S I O C P S uppliers I nputs P rocess O utputs C ustomers

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 #

27. Map Process (Contd.) – Mapping Icons © 2007 Pearson Education

30. Collect & Map Data (Customer & Supplier)

31. Map Information Flow

33. Result - Current State © 2007 Pearson Education A Representative Current State Map for a Family of Retainers at a Bearings Manufacturing Company

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

38. Line Balancing (Contd.)

42. Improvement Results Morale # steps CT/LT ratio Cycle time Lead time % Improvement Future State Current State Metric

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