Value Stream Mapping Training - ADDVALUE - Nilesh Arora

Best Performing Consulting Organization

by

“Value Stream Mapping”

Adding Value In Totality !!

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1. Introduction

2. The Current State Map

3. Lean Value Stream

4. The Future State Map

5. Achieving the Future State

6. Conclusion

Learning Framework

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Value Stream MappingPurpose :

1. Introduce Value Stream

Mapping in a hands on

manner.

2. Develop your ability to

“see the flow” and

design future state value

streams.

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VALUE-STREAM IMPROVEMENT VALUE-STREAM IMPROVEMENT and PROCESS IMPROVEMENTand PROCESS IMPROVEMENT

RawMaterial

PROCESS

VALUE STREAMVALUE STREAMVALUE STREAMVALUE STREAM

FinishedProduct

PROCESSPROCESS

Stamping Welding AssemblyCell

The Three Value Streams: Raw Material to Finished ProductConcept to LaunchOrder to Cash

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Value Stream Mapping

Follow a “products” production path from beginning

to end, and draw a visual representation of every

process in the material & information flow.

Then, draw (using icons) a “future state” map of

how value should flow.

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Using the Value Stream Mapping Tool

Understanding how the shop floor currently operates. The foundation for the future state.

Product “Family”

plan and implementatio

n

Designing a lean flow.

current state drawing

future state drawing

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Process Steps & EquipmentSpot Weld

Robot Weld

Flash Remove

Paint Manual Assm.

Fixtures Assm.

Electronic Test

LH Steering Bracket

RH Steering Bracket

Instrument Panel Brace

Seat

Rail

Bumper Brackets

Focus on One Product FamilyDetermine Product Families via :Similar downstream “assembly” steps and equipment

PR

OD

UC

TS

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Process level

Single plant (door to door)

Multiple plants

Across companies

Levels of a Value Stream

Mapping level to start

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1. Introduction & Getting Started

2. The Current State Map

3. Lean Value Stream

4. The Future State Map

5. Achieving the Future State

6. Conclusion

Learning Framework

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Push

Time

Current-State Map

showing the Customer

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Current State Mapping 1. Mapping the current state :

• Review the basic processing steps and calculate the takt time in your team’s breakout room.

• Everyone draw while on the shop floor. Be sure to draw both the material & information flows.• Always introduce yourself to operators and tell them what you are

doing : “Drawing the total factory flow as part of a training session.’ Show them your drawings.

• Select a scribe and combine your drawings into one current state map (in team area).

• Calculate total lead time versus processing time.• Make an overhead transparency of the map and select presenters.

Team Tips

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Current State Mapping

2. Presenting your

• All team members go up front with presenter. State the product

family and takt.

• Present from your overhead transparency. (Less than 5 minutes.)

• Start with the customer and information flow into the facility.

• State the lead time vs. processing time.

• What are the problems you see? Where did you find push and

overproduction ?

• Share any future state thoughts you have so far.

Team Tips

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Value Stream Loops

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Load-leveling box

One row per product

type

KanbanOne column per pitch here pitch = 10 min

Kanban are responded to from left to right at pitch increment

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An Example of “Paced Withdrawal”

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VALUE ADDED COACHING-VAC®

BUSINESS COACHING LIFE COACHING

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BusinessExcellence

Counselling

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Astrology

Adding Value In Totality !!

Best Performing Consulting Organization

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Thank You