1.
1
Lean-Insight.com
Lean Six Sigma Training
Part 4

2.
2
Drawing a Current State Map

3.
3
Drawing a Current State Map

4.
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.
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 I
Order Entry Proposal Confirmation

6.
6
Order Entry Process – Value Stream Map
Customer
Receive Order Write Down
Order
Part# Lookup Plant Order
Review
Contact
Customer
Enter Order
III
50
= 24 III
125
III
55
III
60
III
35
= 24 = 24 = 4 = 24 = 5
DOR = 25”
Resources = 24
Quality = 50%
DOR = 120”
Resources = 24
Quality = 98%
N/A
Resources = 24
Quality = 90%
DOR = 600”
Resources = 4
Quality = 95%
DOR = 200”
Resources = 24
Quality = 95%
DOR = 60”
Resources = 4
Quality = 92%
III
75
34 Min.
20 Secs
23 Min. 57 Min. 25 Min. 27 Min. 16 Min.
21 Secs 25 Secs 600 Secs 19 Secs 22 Secs
Lead
Time
Proc.
Time
= 182 Min
= 12 Min.
TAKT Time
27,000 sec
990 lines
= 27.3 sec=
Daily Orders
(fax/phone)
Request Status
(fax/phone/email)
CS Order
Mgmt
System
Plant Order
Mgmt System
CS Order
Mgmt System
19,800 lines/Mo
MRP

7.
7
Prioritize Improvement Opportunities
Prod’n Cont.
Suppliers
OPSI
CRC
Prod’n Cont.
HLAGEC Weekly
Orders
4 WEEK
FORECAST
MRP
Daily
Orders
13 WEEK
FORECAST
Customer
Forecast
Orders
Sales
13 WEEK FORECAST
Daily
SHIP
30 Min. 1020 Min. 25 Min. 30 Min.
Daily
Schedule
6
TEST CONFASSY
10 Days 10 Days 5 Days
6 4 2
Ass’y WIP
210 Units
$513,000
3 Days Worth
Brds + RIP
$3,300,000
19 Days Worth
Test WIP+FG
$1,700,000
10 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
$425,000
11 Days Worth
Non-Value Add
1,020 Hrs. (98% of Time)
Value Add 20
Hrs. (2% of Time)
Long
Set Ups
SMED
Too Much
Inventory
Create Supermarket
Too Much
Variation
Heijunka

8.
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 your
customers like
to experience?

9.
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.
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/