Value Stream Mapping

Six Steps to Lean

Value Stream Mapping Icons OPS460 > Course Documents > Visio Tutorials > Value Stream Mapping Icons

Furniture Value Steam Furniture Manufacturing Current State Map

Material and Information flows

Acme Current State Map

EMC Supply Assignment

Exercise-Flextronics Solution

Value Stream Mapping Process Product Family Current State Drawing Work Plan & Implementation Future State Drawing Understand how the value currently flows Design a Lean flow Plan how to get there and execute the plan Define the Value Stream

Crane Aerospace Value Stream Map

Crane Aerospace Value Stream Map Detailed

OEE Elements

OEE Example

Value Stream Mapping Process Product Family Current State Drawing Work Plan & Implementation Future State Drawing Understand how the value currently flows Design a LEAN flow Plan how to get there and execute the plan Define the Value Stream

Future State Icons

Takt Time

Acme Takt Time 60 seconds 27,600 sec 460 pieces

Build to Shipping or Supermarket 20 Kanban based on customer packaging 20-bracket tray 20

Continuous Flow Processing Batch-and-Queue Processing Process time/product = 1 min Original Batch = 10 parts Revised Batch = 1 part

Alternative Work Combinations Split the Work

Staffing for Increased Demand Combination Split the Work and Circuit

Supermarket

Number of Kanban Card Sets k = Expected demand during lead time + Safety Stock Size of container k = D  L ( 1 + S ) C k = Number of kanban card sets (a set is a card) D = Average number of units demanded over some time period L = Lead time to replenish an order (same units of time as demand) S = Safety stock expressed as a percentage of demand during lead time C = Container size

Kanban Calculations k = Expected demand during lead time + Safety Stock Size of container k = D  L ( 1 + S ) = 5 (2) (1.10) = 2.75 or 3 C 4

Acme Supermarkets Coils Supermarket Finished Goods Supermarket Stamped Parts Supermarket Milk Run

First In, First Out (FIFO) Lane An Example of a “First In, First Out (FIFO) Lane”

Scheduling Schedule Schedule

Mixed Production Pacemaker Process! 50B 70A 80C 50B 70A 80C

Leveling the Volume = Takt Time • Pack Size

Implementation Process Value Stream Manager Point Kaizen

Acme Future-State Map

Acme Future State Performance

House of Lean-5S

Six Steps to Lean

Meaning of the 5S’s Sort Simplify Sweep Standardize Self-Discipline

Example of a Red Tag RED TAG

Red Tag and Signboard Strategies

Dilbert – 5S Program

Types of Simplifying Type Identification Markers Location Markers Quantity Markers Standard Methods Tags Andon Kanban Performance Display Defect Display Personnel Board Examples Signboards, name labels, photos, or shapes of items. Tape strips, color coding, numbering. Signs indicating number (min/max), standard files, number of spaces for items indicators of normal operating values. Charts of cycle time and work sequence, standard procedures, flowcharts, photos of operation or process flows. Errors, excess or extremes (red flag), “broken” items or process Visual (lights, flags) and audio (bells, buzzers, tones) signals to draw immediate attention for help. Card, empty container or blank information space signaling that activity or Process schedule and quantities, quality, costs, safety, or improvement activities. Tables or boards or other forum / venue showing defective processes, information, or paperwork. Availability (in/out), assignment and location of department personnel, cross-training status vs. plan. movement is authorized.

Inventory Signboards

Boeing-Point of Use Standard Responsibility, Authority, Accountability (RAA) Placard Color Code Flag

Crane 4-819 RHGS Incoming Material Before 5S After 5S Inventory Signboards

Shadow Boards and Identification Shadow board

Crane Aerospace Shadow Board Lazy Susan for hand tools

Boeing-Shadow Boxes Tool Pallet Kit Examples

Crane Simplify, Arrange, Identify Arrange and Identify for ease of use “ Anyone should be able to easily understand proper arrangement and sub-optimal arrangement.”

Crane Level 3 Office “ The Goal”

Visible Workplace “ With the 5S’s implemented, we have an easy to observe gemba (workplace), and the andon clearly shows where and when we have problems” Andon Jidoka Gemba 5S’s

Crane 5S Level of Factory Excellence