Value Stream Mapping to Create Value and Eliminate Muda

Value-Stream Mapping to

Create Value and Eliminate

Muda

Presentedby

Mohammed El Boussami

Hafez Shurrab

Introduction

Value Stream

Mapping

Seven wastes

Supply Chain

Why Value Stream Mapping

• Information & materials relation

• Identify Wastes

• Continuous Improvement

Five Steps to do Value Stream Mapping

• Product Family

• Current State Map

• Future State Map

• Plan

• Value Stream Map

CASE STUDY: ACME STAMPING

& WIRE FORMING CO.

• Acme has been incorporated in 1921

• Metal Stamping, CNC Machining, &

Wire Forming

• Mass Prodcution & Push Systems

• Lean Manucaturing & Pull Systems

Process

Cycle

Time

(sec.)

Changeover Time(sec.)

Uptime (%)

WIP next to the process

(unit), L: lift, R: right

(D): Day of Demand

Stamping1 3600 85 4600 L - 2400 R 7.6 D

Welding “1”

39 600 100 1100 L - 600 R 1.8 D

Welding “2”

46 600 80 1600 L - 850 R 2.7 D

Assembly “1”

62 - 100 1200 L - 640 R 2 D

Assembly “2”

40 - 100 2700 L - 1440 R 4.5 D

The data of Acme's Production Processes

Current State Map

Guiding Questions

• What is the takt time of Acme for the selected product family?

• Should Acme build steering brackets directly to shipping or to

a finished goods supermarket/buffer?

• Where could continuous flow be introduced?

• Where buffers would be set?

• What the pacemaker process?

• How should Acme level the production mix?

• What consistent increment of work should be released?

• What process improvements will be necessary?

Load-Leveling Box

shift 1 7 720 740 8 820 840 910 930

shift 2 4 420 440 5 520 540 610 630

Left Drive

  L L   L L   L

Right Drive

R     R     R  

Future State Map

Acme Stamping Lead-Time Improvement

 Locatio

nCoil

Stampe

d Parts

Wie/

Ass.

WIP

Finishe

d

Goods

Producti

on Lead

Time

Total

Invento

ry

Turns

Before 5 Days7.5

Days

6.5

Days

4.5

Days

23.6

Days10

Continuou

s Flow &

Pull

2 Days1.5

Days0

4.5

Days8 Days 30

With

Leveling

1.5

Days1 Day 0 2 Days 4.5 Days 53

Conclusion

• VSM is highly recommended tool to eliminate muda.

• There should be high cooperation between all business

owners in the supply chain.

• VSM guides to which tools and practices could be effeciently

incorporated.

• Kaizen targets should be given high priorities.

• VSM could be also helpful for intelligent benchmarking.

Conclusion (cont.)

• Some concerns are:

The diversity of indusries

characteristics

Technological limits

Resistance to change

The accessibility of data