Value Stream Mapping AGENDA. ! Introduction to mapping. ! Creating a Current State Map. ! Introduction To Lean Techniques

Transcription

1 Value Stream Mapping AGENDA! ntroduction to mapping! Creating a Current State Map! ntroduction To Lean Techniques! Creating a Future State Map! Using a Map as a basis for Tactical mplementation Planning

2 Future State Value Stream Mapping THE 9 KEY QUESTONS :. What are the customer requirements 2. How to apply Continuous Flow Processing 3. Which process is the pacemaker 4. How to control upstream processes 5. What size supermarkets (shop stock) are required 6. s it sequential or fill-up pull 7. Where to level production 8. At what frequency will kanban be released 9. What further improvements can be made

3 Creating a Future State Value Stream Map THE 7 STEPS. Customer Requirements 2. Draw Process Steps 3. Process Data 4. nventory 5. Material Flow: Supplier to Manufacturer & Manufacturer to Customer 6. nformation Driving Flow & nternal Material Flow 7. Manufacturing Lead Time & Processing Time

4 cons for use in Future State Supermarket with Prod Card & Withdrawal card FFO First n First Out sequence flow Kanban Post 300 pieces Day nventory Pull Symbol XYZ corporation Outside sources Supermarket with Prod Card Supermarket PUSH arrow Signal Kanban Min & Max CHANGEOVER Kaizen lightening burst Mon + Wed Truck Shipment Production Control Production Control nformation System VSM Symbols Electronic information flow abc OXOX 4 Level loading Production 4 4 Manual nformation flow Sequenced-Pull Ball Ref.ppt

5 Go to white board and change current state to future state. Ask the delegates to draw it with you

6 Current State Map Coils r us 6 week forecast Weekly fax Production Planning 30/ 60/ 90 day forecast expedite F.A.L. 500 ft coils MRP Weekly plan 6 pieces/ day 320 pieces/ month 200 A 20 A2 Tuesday and Thursday 2 shifts Pack size = shipping plan Stamping 5 days 50 A 0 T 24 A2 Spot weld # 42 A 6 A2 Spot weld # 2 6 A 8 A2 Assembly # 42 A 6 A2 Assembly # 2 27 A 4 A2 Shipping 5 days Cycle time= minute Change over= hour Uptime =85% Cycle time= 39 minute Change over=0 min. Uptime =00% Cycle time= 46 minute Change over=0 min. Uptime =80% Cycle time= 62 minute Change over=0 min. Uptime =00% Cycle time= 40 minute Change over=0 min. Uptime =00% Production Lead Time = 26.6 days Processing time = 88 mins 0.9 days 3 days 2. days 3 days 2.6 days minute 39 minute 46 minute 62 minute 40 minute Slug Brackets Stamping Currents State Map Date :.

7 Add Takt Calculation Coils r us 6 week forecast Weekly fax Production Planning 30/ 60/ 90 day forecast expedite F.A.L. 500 ft coils MRP Weekly plan 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces 320 pieces/ month 200 A 20 A2 Tuesday and Thursday Pitch = 57.5 mins x pieces = 57.5 mins 2 shifts Pack size = x shipping plan Stamping 5 days 50 A 0 T 24 A2 Spot weld # 2 42 A 6 A2 Spot weld # 2 6 A 8 A2 Assembly # 2 42 A 6 A2 Assembly # 27 A 4 A2 Shipping 5 days Cycle time= minute Change over= hour Uptime =85% Cycle time= 39 minute Change over=0 min. Uptime =00% Cycle time= 46 minute Change over=0 min. Uptime =80% Cycle time= 62 minute Change over=0 min. Uptime =00% Cycle time= 40 minute Change over=0 min. Uptime =00% Production Lead Time = 26.6 days Processing time = 88 mins 0.9 days 3 days 2. days 3 days 2.6 days minute 39 minute 46 minute 62 minute 40 minute Slug Brackets Stamping Currents State Map Date :.

8 Where is Continuous Flow Possible?! DRAW ON FLP CHART 57.5 min. Takt 39 min. 46 min. 62 min. 40 min. min. Stamp SW SW 2 Assy. Assy. 2

9 Drawing a Future State Map Coils r us 500 ft coils 6 week forecast Weekly fax MRP Production Planning Weekly plan 30/ 60/ 90 day forecast expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces F.A.L. 320 pieces/ month 200 A 20 A2 Tuesday and Thursday Pitch = 57.5 mins x pieces = 57.5 mins 2 shifts Pack size = shipping plan Stamping 5 days 50 A 0 T 24 A2 Spot weld # A 6 A2 Spot weld # 2 6 A 8 A2 Assembly # 2 42 A 6 A2 Assembly # 27 A 4 A2 Shipping 5 days Cycle time= minute Change over= hour Uptime =85% Cycle time= 39 minute Change over=0 min. Uptime =00% Cycle time= 46 minute Change over=0 min. Uptime =80% Cycle time= 62 minute Change over=0 min. Uptime =00% Cycle time= 40 minute Change over=0 min. Uptime =00% Production Lead Time = 26.6 days Processing time = 88 mins 0.9 days 3 days 2. days 3 days 2.6 days Slug Brackets Stamping Currents State Map Date :.

14 Where is Continuous Flow Possible? deal No. Of Operators = Total Work Content Takt Time e.g. deal No. Of Operators = 87 minutes of work 57.5 minutes Takt = 3.25 operators x = 4 = target of 3

15 Where is Continuous Flow Possible?! DRAW ON FLP CHART 57.5 min. Takt (55 X 3) + 22 = 87 minutes min. 8 min. Takt Cycle Time SW 2 25 min. Assy. 2 Assy. 39 min. 30 min. 37 min. 22 min. min. SW SW 2 Assy. Assy. 2 Stamp

17 Drawing a Future State Map Coils r us 500 ft coils 6 week forecast Weekly fax MRP Production Planning Weekly plan 30/ 60/ 90 day forecast expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces F.A.L. 320 pieces/ month 200 A 20 A2 Tuesday and Thursday Pitch = 57.5 mins x pieces = 57.5 mins shipping plan 2 shifts Pack size = Weld+ assy. 5 days Stamping 0 T Cycle time= minute Change over= hour Uptime =85% SW C/O TT= 60 minute C/T=55 min 4x SW 2 uptime Work content To 55 min. 2 days Shipping Target 3 Ops Slug Brackets Stamping Currents State Map Date :.

18 Drawing a Future State Map Coils r us 500 ft coils 6 week forecast Weekly fax MRP Production Planning Weekly plan 30/ 60/ 90 day forecast expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces F.A.L. 320 pieces/ month 200 A 20 A2 Tuesday and Thursday Pitch = 57.5 mins x pieces = 57.5 mins shipping plan 2 shifts Pack size = Weld+ assy. 5 days Stamping 0 T Cycle time= minute Change over= hour Uptime =85% SW C/O TT= 60 minute C/T=55 min 4x SW 2 uptime Work content To 55 min. 2 days Shipping Target 3 Ops Slug Brackets Stamping Currents State Map Date :.

19 Drawing a Future State Map 6 week forecast Production Planning 30/ 60/ 90 day forecast F.A.L. 500 ft coils Weekly fax MRP Weekly plan expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces 320 pieces/ month 200 A 20 A2 Tuesday and Thursday Pitch = 57.5 mins x pieces = 57.5 mins shipping plan 2 shifts Pack size = Weld+ assy. 5 days Stamping 0 T Cycle time= minute Change over= hour Uptime =85% SW C/O TT= 60 minute C/T=55 min 4x SW 2 uptime Work content To 55 min. 2 days Shipping Target 3 Ops Slug Brackets Stamping Currents State Map Date :.

20 Drawing a Future State Map Coils r us 500 ft coils 6 week forecast Weekly fax MRP Production Planning Weekly plan 30/ 60/ 90 day forecast expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces F.A.L. 320 pieces/ month 200 A 20 A2 Tuesday and Thursday batch Pitch = 57.5 mins x pieces = 57.5 mins shipping plan 2 shifts Pack size = Weld+ assy. 5 days Stamping 0 T Cycle time= minute Change over= hour Uptime =85% SW C/O TT= 60 minute C/T=55 min 4x SW 2 uptime Work content To 55 min. 2 days Shipping Target 3 Ops Slug Brackets Stamping Currents State Map Date :.

21 Drawing a Future State Map Coils r us 500 ft coils 6 week forecast Weekly fax MRP Production Planning Weekly plan 30/ 60/ 90 day forecast expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces F.A.L. 320 pieces/ month 200 A 20 A2 Tuesday and Thursday batch Pitch = 57.5 mins x pieces = 57.5 mins shipping plan 2 shifts Pack size = Weld+ assy. 5 days Stamping 0 T Cycle time= minute Change over= hour Uptime =85%.5 days SW C/O TT= 60 minute C/T=55 min 4x SW 2 uptime Work content To 55 min. 2 days delivery trays Shipping Target 3 Ops Slug Brackets Stamping Currents State Map Date :.

22 Drawing a Future State Map Coils r us 500 ft coils 6 week forecast Weekly fax MRP Production Planning Weekly plan 30/ 60/ 90 day forecast expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces F.A.L. 320 pieces/ month 200 A 20 A2 Tuesday and Thursday batch Pitch = 57.5 mins x pieces = 57.5 mins Shipping plan 2 shifts Pack size = Weld+ assy. 5 days Stamping 0 T Cycle time= minute Change over= hour Uptime =85%.5 days SW C/O TT= 60 minute C/T=55 min 4x SW 2 uptime Work content To 55 min. 2 days delivery trays Shipping stage Target 3 Ops Slug Brackets Stamping Currents State Map Date :.

23 Drawing a Future State Map Coils r us 500 ft coils 6 week forecast Weekly fax MRP Production Planning Weekly plan 30/ 60/ 90 day forecast expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces F.A.L. 320 pieces/ month 200 A 20 A2 Tuesday and Thursday batch Pitch = 57.5 mins OOXXOOXX Pitch = 57.5 mins x pieces = 57.5 mins Shipping plan 2 shifts Pack size = 2 Weld+ assy days Stamping 0 T Cycle time= minute Change over= hour Uptime =85%.5 days SW C/O TT= 60 minute C/T=55 min 4x SW 2 uptime Work content To 55 min. 2 days delivery trays Shipping stage Target 3 Ops Slug Brackets Stamping Currents State Map Date :.

24 Drawing a Future State Map Coils r us 6 week forecast Production Planning 30/ 60/ 90 day forecast expedite F.A.L. 500 ft coils MRP Weekly plan 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces 320 pieces/ month 200 A 20 A2 batch Pitch = 57.5mins OOXXOOXX Pitch = 57.5 mins x pieces = 57.5 mins Shipping plan 2 shifts Pack size = Weld+ assy..5 days Stamping 0 T Cycle time= minute Change over= hour Uptime =85%.5 days SW C/O TT= 60 minute C/T=55 min 4x SW 2 uptime Work content To 55 min. 2 days delivery trays Shipping stage Target 3 Ops Slug Brackets Stamping Currents State Map Date :.

25 Drawing a Future State Map Coils r us 6 week forecast Production Planning 30/ 60/ 90 day forecast expedite F.A.L. 500 ft coils MRP 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces 320 pieces/ month 200 A 20 A2 batch Pitch = 57.5 mins OOXXOOXX Pitch = 57.5 mins x pieces = 57.5 mins Shipping plan 2 shifts Pack size = Weld+ assy..5 days.5 days Stamping Cycle time= minute Change over= hour Uptime =85% 0 T min.5 days.5 days SW C/O TT= 60 minute C/T=55 min 4x 65 min SW 2 uptime Target 3 Ops Work content To 55 min. 2 days 2 days delivery trays Shipping stage 5 days 66 minutes Slug Brackets Stamping Currents State Map Date :.

26 Value Stream Mapping Delegates to design own future state map

27 Developing an mprovement Plan Current State Map Future State Map Gap Analysis... WHERE WLL YOU START?

28 Dividing a Future State Map F.A.L. 500 ft coils 6 week forecast Supplier loop MRP Production Planning 30/ 60/ 90 day forecast expedite 6 pieces/ day Takt = 2(480-20)minutes = 57.5 mins 6 pieces F.A.L. 320 pieces/ month 200 A 20 A2.5 days.5 days Stamping 0 T loop.5 days Cycle time= minute Change over= hour Uptime =85% batch Stamping min.5 days 2 shifts Pitch = 57.5 mins Pack size = OOXXOOXX Shipping plan Pacemaker loop Weld+ assy. SW C/O TT= 60 minute C/T=55 min 3x 65 min SW 2 uptime Target 3 Ops Work content To 55 min. Pitch = 57.5 mins x pieces = 57.5 mins 2 days 2 days delivery trays Shipping stage 5 days 66 minutes Slug Brackets Stamping Currents State Map Date :.

29 Value Stream Mapping AGENDA! ntroduction to mapping! Creating a Current State Map! Practical Exercise! ntroduction To Lean Techniques! Creating a Future State Map! Using a Map as a basis for Tactical mplementation Planning

30 Why Have a Formal Plan to Achieve the future State? To set the team direction To show a relevant level of detail to those concerned - NB. each loop will have it s own execution schedules within the implementation plan To encourage regular reviews for signs of QCD problems - slippage's, early deliveries, continued ownership To formalise commitment from key people: Facility Manager Value stream manager The Unions Manufacturing Engineering Maintenance Process Engineering Purchasing The key elements of a Value Stream s mplementation plan are shown in the following example.

31 Example - Tactical mplementation Type of TPPlan (T..P.) and Model Line Level Activity TP Owner 5C Activity Level 2 Detailed Actions Responsible People Timebased Schedule of activities Category

32 Summary! Collect data across a value stream.! Use the 7 steps to draw a current state Value Stream Map.! Use the 9 questions and 7 steps to draw a future state Value Stream Map.! dentify your Material/nformation loops.! Decide the order to tackle the loops.! Write the Tactical mplementation Plan Set objectives for each loop as required to achieve the future state Set measurable goals for each objective Use the 9 questions within each loop to set an order of work Set milestones and write up the plan Get formal agreement from all concerned! The leader of each work stream should produce their own execution schedule showing how to achieve each goal by it s milestone.

33 Value Stream Mapping AGENDA! ntroduction to mapping! Creating a Current State Map! Practical Exercise! ntroduction To Lean Techniques! Creating a Future State Map! Using a Map as a basis for Tactical mplementation Planning

34 Summary Just do it!