Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.c om ∙ VALUE STREAM MAPPING ∙ L
Jul 25, 2015
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
∙ VALUE STREAM MAPPING ∙
L
WHAT TO EXPECT…
Define Lean Six Sigma
What is Value-Add and Non Value-Add Activity
Value-Add vs Non Value-Add (NVA = Waste)
Eliminating Non Value-Add Activity
Time Reduction. Why is it important?
Value Stream Mapping, a tool of Lean Six Sigma.
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
EVOLUTION OF CONTINUOUS IMPROVEMENT
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
LEAN SIX SIGMA 101
LEAN SIX SIGMA is a disciplined continual improvement method that resulted from the combined effort of lean and six sigma.
1) Lean works to improve any process by identifying and eliminating waste using various techniques designed to be applied directly at any level of business.
2) Six Sigma works to improve any business process by identifying and reducing variability through the deliberate and systematic application of statistical problem solving.
THE COMMON THREAD CONNECTING THESE TWO METHODS IS THE CONTINUOUS AND RELENTLESS PURSUIT FOR PERFECTION.
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
Value-Adding Activities......transform raw materials and information into products or services
which the customer wants!
Non-Value-Adding Activities......consume resources, but don't directly contribute to the product.
Necessary Non-Value-Adding Activities……activities that do not add value but are required due to current process
design, government regulations, or for other reasons.
VALUE-ADD vs. NON VALUE-ADD
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
Value-Adding Activities......transform raw materials and information into products or services
which the customer wants!
Non-Value-Adding Activities......consume resources, but don't directly contribute to the product.
Necessary Non-Value-Adding Activities……activities that do not add value but are required due to current process
design, government regulations, or for other reasons.
VALUE-ADD vs. NON VALUE-ADD
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
WASTE - A DEEPER LOOK
“Transactional Process Waste”
• Layout (distance)
• Long setup times
• Incapable processes
• Poor operating practices
• Poor communication
• Lack of training
• Lack of adherence
• Irrelevant performance measures
• Ineffective production planning/scheduling
• Lack of workplaceorganization
• Quality/Reliability Issues• Unreliable equipment• More…
“If it doesn’t add value, it’s waste.” Henry Ford 1920
CAUSES OF WASTE
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
ADDITIONAL COSTS OF POOR PERFORMANCE
Lost Opportunity
Scrap
Rework
Inspection
Rejects
Lost Sales
Long Cycle Times
Expediting Costs
Excess Inventory
Lost Customer Loyalty
More Set-ups
Additional Material Costs
Excessive Material Planning
Warranty
Late Delivery
TRADITIONAL COST OF POOR PERFORMANCE
Additional Inspection
Obsolete Material
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
SEA OF WASTE
ADDITIONAL COST OF POOR PERFORMANCE
Lost Opportunity
Scrap
Rework
Inspection
Rejects
Lost Sales
Long Cycle Times
Expediting Costs
Excess Inventory
Lost Customer Loyalty
More Set-ups
Additional Material Costs
Excessive Material Planning
Warranty
Late Delivery
TRADITIONAL COST OF POOR PERFORMANCE
Additional Inspection
Obsolete Material
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
VALUE-ADD vs. NON VALUE-ADD
Kaizen Waste Reduction
Traditional Manufacturing Improvement
Typical Company
Value-Adding Activities Non-Value-Adding Activities
TYPICAL BUSINESS IMPROVEMENT
TYPICAL BUSINESSACTIVITY
LEAN SIX SIGMA IM-PROVEMENT
MajorImprovement
1% Improvement
0.5%
10%Minor
Improvement
REDUCING NON VALUE-ADD ACTIVITY
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
99%
99.5%
90%
(the business focuses on the value add)
Time is the single best indicator of competitiveness!
1 Hour – 2 Hour – 3 Hour ….
Kaizen Waste Reduction
Traditional Manufacturing Improvement
Typical Company
Value-Adding Activities Non-Value-Adding Activities
TYPICAL BUSINESS IMPROVEMENT
TYPICAL BUSINESSACTIVITY
LEAN SIX SIGMA IM-PROVEMENT
MajorImprovement
1%
0.5%
10%Minor
Improvement
REDUCING NON VALUE-ADD ACTIVITY
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
99%
99.5%
90%
(focus on reducing the value-add time)
Kaizen Waste Reduction
Traditional Manufacturing Improvement
Typical Company
Value-Adding Activities Non-Value-Adding Activities
TYPICAL BUSINESS IMPROVEMENT
TYPICAL BUSINESSACTIVITY
LEAN SIX SIGMA IM-PROVEMENT
MajorImprovement
1%
0.5%
10%Minor
Improvement
REDUCING NON VALUE-ADD ACTIVITY
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
99%
99.5%
90%
(the business focuses on the value add)
LEAN SIX SIGMA STEPS
Value Stream Mapping www.opexdirect.comA Lean Six Sigma Consulting and Engineering Firm
1. Identify the sequence of activities called the “Value Stream"
2. Identify which activities create value (VALUE-ADD)
3. Make the activities Flow
• Eliminating waste and reducing variation (NON VALUE-ADD)
4. Create Pull throughout the Value Stream
5. Perfect the Process
LEAD TIME
WASTE ELIMINATION = TIME REDUCTION
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
1 MONTH
LEAD TIME
WASTE ELIMINATION = TIME REDUCTION
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
1 MONTH
LEAD TIME
WASTE ELIMINATION = TIME REDUCTION
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
1 MONTH
COMMUNICATION & INFORMATION STEPS
LEAD TIME
WASTE ELIMINATION = TIME REDUCTION
PROCESSING (SERVICE/MANUFACTURING) STEPS
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
1 MONTH
COMMUNICATION & INFORMATION STEPS
VALUE STREAM
LEAD TIME
WASTE ELIMINATION = TIME REDUCTION
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
1 MONTH
VALUE STREAM
LEAD TIME
WASTE ELIMINATION = TIME REDUCTION
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
1 MONTH
The Process is the Focus of Lean Six Sigma WASTE elimination activity!
Value-Adding Activities......transform raw materials and information into products or services
which the customer wants!
Non-Value-Adding Activities......consume resources, but don't directly contribute to the product.
Necessary Non-Value-Adding Activities……activities that do not add value but are required due to current process
design, government regulations, or for other reasons.
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
WASTE ELIMINATION = TIME REDUCTION
LEAD TIME
NON VALUE-ADD
VALUE-ADD
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
WASTE ELIMINATION = TIME REDUCTION
1 MONTH
Identify what is --------->
Identify what is --------->
LEAD TIME
VALUE-ADD
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
WASTE ELIMINATION = TIME REDUCTION
1 MONTH
ELIMINATE NON VALUE-ADDED ACTIVITY IN THE VALUE STREAM
LEAD TIME
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
WASTE ELIMINATION = TIME REDUCTION
1 MONTH
VALUE-ADD
LEAD TIME
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
WASTE ELIMINATION = TIME REDUCTION
1 MONTH
LEAD TIME REDUCTION FROM 1 MONTH TO 5 DAYS
LEAD TIME
5 DAYS
LEAD TIME
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
WASTE ELIMINATION = TIME REDUCTION
1 MONTH
NEW VALUE STREAM
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
VALUE STREAM MAP EXAMPLE
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
VALUE STREAM MAP EXAMPLE
SEARCH FOR IMPROVEMENT OPPORTUNITIES (LEAN SIX SIGMA)
IdentifyFocusArea
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
SEARCH FOR IMPROVEMENT OPPORTUNITIES (LEAN SIX SIGMA)
VALUE STREAM MAP EXAMPLE
FocusProcess
MapFocus Area
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
VALUE STREAM MAP EXAMPLE
SEARCH FOR IMPROVEMENT OPPORTUNITIES (LEAN SIX SIGMA)
FocusProcess
MapFocus Area
Value Stream Mapping A Lean Six Sigma Consulting and Engineering Firm www.opexdirect.com
VALUE STREAM MAP EXAMPLE
SEARCH FOR IMPROVEMENT OPPORTUNITIES (LEAN SIX SIGMA)
LEAN SIX SIGMA EFFORT