Introduction to mapping

1
Value Stream Mapping
AGENDA

• Introduction to mapping
• Creating a Current State Map
• Introduction To Lean Techniques
• Creating a Future State Map
• Using a Map as a basis for Tactical
  Implementation Planning

2
Future State Value Stream Mapping
THE 9 KEY QUESTIONS
1. What are the customer requirements 2. How to
apply Continuous Flow Processing 3. Which
process is the pacemaker 4. How to control
upstream processes 5. What size supermarkets
(shop stock) are required 6. Is it sequential or
fill-up pull 7. Where to level production 8. At
what frequency will kanban be released 9. What
further improvements can be made
3
Creating a Future State Value Stream Map

• THE 7 STEPS
• Customer Requirements
• Draw Process Steps
• Process Data
• Inventory
• Material Flow Supplier to Manufacturer
  Manufacturer to Customer
• Information Driving Flow Internal Material
  Flow
• Manufacturing Lead Time Processing Time

4
Icons for use in Future State
Supermarket with Prod Card Withdrawal card
XYZ corporation
First In First Out sequence flow
300 pieces 1Day
Kanban Post
Pull Symbol
Inventory
Outside sources
Mon Wed
CHANGEOVER
Signal KanbanMin Max
Supermarket
Truck Shipment
Kaizen lightening burst
Supermarketwith Prod Card
PUSH arrow
Information System VSM Symbols
Production Control
Electronic information flow
Level loading Production
Manual Information flow
Sequenced-Pull Ball
Ref.ppt
5
Go to white board and change current state to
future state. Ask the delegates to draw it with
you
6
Current State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
16 pieces/ day
500 ft coils
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
Shipping
Stamping
Assembly 2
Assembly 1
Spot weld 2
Spot weld 1
5 days
150 A1 24 A2
42 A1 6 A2
16 A1 18 A2
42 A1 6 A2
27 A1 14 A2
10 T
Production Lead Time 26.6 days
Processing time 188 mins
3 days
2.6 days
2.1 days
3 days
5 days
10.9 days
1 minute
39 minute
46 minute
62 minute
40 minute
Slug Brackets Stamping Currents State Map Date
.
7
Add Takt Calculation
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax

• 320 pieces/ month
• 200 A1
• 120 A2

16 pieces/ day
MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces 57.5
mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
x
Daily shipping plan
Shipping
Stamping
Assembly 1
Assembly 2
Spot weld 2
Spot weld 2
5 days
150 A1 24 A2
42 A1 6 A2
16 A1 8 A2
42 A1 6 A2
27 A1 14 A2
10 T
Production Lead Time 26.6 days
Processing time 188 mins
3 days
2.6 days
2.1 days
3 days
5 days
10.9 days
1 minute
39 minute
46 minute
62 minute
40 minute
Slug Brackets Stamping Currents State Map Date
.
8
Where is Continuous Flow Possible?

• DRAW ON FLIP CHART

62 min.
57.5 min. Takt
46 min.
40 min.
39 min.
1 min.
Stamp
SW 1
SW 2
Assy. 1
Assy. 2
9
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
Shipping
Stamping
Assembly 1
Assembly 2
Spot weld 2
Spot weld 2
5 days
150 A1 24 A2
200 A1 6 A2
16 A1 8 A2
42 A1 6 A2
27 A1 14 A2
10 T
Production Lead Time 26.6 days
Processing time 188 mins
3 days
2.6 days
2.1 days
3 days
5 days
10.9 days
Slug Brackets Stamping Currents State Map Date
.
10
Where is Continuous Flow Possible?

• DRAW ON FLIP CHART

62 min.
57.5 min. Takt
46 min.
39 min.
40 min.
1 min.
Stamp
SW 1
SW 2
Assy. 1
Assy. 2
11
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
Shipping
Stamping
Assembly 1
Assembly 2
Spot weld 2
Spot weld 2
5 days
150 A1 24 A2
200 A1 6 A2
16 A1 8 A2
42 A1 6 A2
27 A1 14 A2
10 T
Production Lead Time 26.6 days
Processing time 188 mins
3 days
2.6 days
2.1 days
3 days
5 days
10.9 days
Slug Brackets Stamping Currents State Map Date
.
12
Where is Continuous Flow Possible?

• DRAW ON FLIP CHART

62 min.
57.5 min. Takt
46 min.
39 min.
40 min.
1 min.
Stamp
SW 1
SW 2
Assy. 1
Assy. 2
13
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
Shipping
Stamping
Assembly 1
Assembly 2
Spot weld 2
Spot weld 2
5 days
150 A1 24 A2
200 A1 6 A2
16 A1 8 A2
42 A1 6 A2
27 A1 14 A2
10 T
Production Lead Time 26.6 days
Processing time 188 mins
3 days
2.6 days
2.1 days
3 days
5 days
10.9 days
Slug Brackets Stamping Currents State Map Date
.
14
Where is Continuous Flow Possible?
Ideal No. Of Operators Total Work Content
Takt
Time e.g. Ideal No. Of Operators 187
minutes of work 57.5 minutes
Takt 3.25 operators
4
target of 3
x
15
Where is Continuous Flow Possible?

• DRAW ON FLIP CHART

(55 X 3) 22 187 minutes
57.5 min. Takt
Takt
55
55
55
Cycle Time
16 min.
18 min.
SW 2
25 min.
Assy. 2
Assy. 1
39 min.
30 min.
22 min.
37 min.
1 min.
SW 2
Assy. 2
Assy. 1
SW 1
Stamp
16
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
Shipping
Stamping
Assembly 1
Assembly 2
Spot weld 2
Spot weld 2
5 days
150 A1 24 A2
200 A1 6 A2
16 A1 8 A2
42 A1 6 A2
27 A1 14 A2
10 T
Production Lead Time 26.6 days
Processing time 188 mins
3 days
2.6 days
2.1 days
3 days
5 days
10.9 days
Slug Brackets Stamping Currents State Map Date
.
17
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
Weld assy.
Shipping
Stamping
TT 60 minute
5 days
10 T
C/T55 min
2 days
4 x
SW C/O
Slug Brackets Stamping Currents State Map Date
.
18
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
1
Weld assy.
Shipping
Stamping
TT 60 minute
5 days
10 T
C/T55 min
2 days
4 x
SW C/O
Slug Brackets Stamping Currents State Map Date
.
19
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
1
1
Weld assy.
Shipping
Stamping
TT 60 minute
5 days
10 T
C/T55 min
2 days
4 x
SW C/O
Slug Brackets Stamping Currents State Map Date
.
20
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
1
batch
Weld assy.
Shipping
Stamping
TT 60 minute
5 days
10 T
C/T55 min
2 days
4 x
SW C/O
Slug Brackets Stamping Currents State Map Date
.
21
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily shipping plan
1
batch
Weld assy.
Shipping
Stamping
TT 60 minute
5 days
10 T
C/T55 min
delivery trays
2 days
4 x
1.5 days
SW C/O
Slug Brackets Stamping Currents State Map Date
.
22
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pack size 1
Daily Shipping plan
1
batch
1
1
1
Weld assy.
Shipping
Stamping
TT 60 minute
5 days
stage
10 T
C/T55 min
delivery trays
2 days
4 x
1.5 days
SW C/O
Slug Brackets Stamping Currents State Map Date
.
23
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
Weekly fax
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Tuesday and Thursday
Pitch 57.5 mins
Pack size 1
Daily Shipping plan
1
OOXXOOXX
batch
1
1
1
1
2
Weld assy.
4
3
Shipping
Stamping
TT 60 minute
5 days
stage
10 T
C/T55 min
delivery trays
2 days
4 x
1.5 days
SW C/O
Slug Brackets Stamping Currents State Map Date
.
24
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
Weekly plan
2 shifts
Daily
Pitch 57.5mins
Pack size 1
Daily Shipping plan
1
OOXXOOXX
batch
1
1
1
Weld assy.
Shipping
Stamping
TT 60 minute
stage
10 T
C/T55 min
delivery trays
2 days
1.5 days
4 x
1.5 days
SW C/O
Slug Brackets Stamping Currents State Map Date
.
25
Drawing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Daily expedite
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
2 shifts
Daily
Pitch 57.5 mins
Pack size 1
Daily Shipping plan
1
OOXXOOXX
batch
1
1
1
Weld assy.
Shipping
Stamping
TT 60 minute
stage
10 T
C/T55 min
delivery trays
2 days
1.5 days
4 x
1.5 days
SW C/O
5 days
166 minutes
2 days
1.5 days
1.5 days
165 min
1 min
Slug Brackets Stamping Currents State Map Date
.
26
Value Stream Mapping
Delegates to design own future state map
27
Developing an Improvement Plan
WHERE WILL YOU START ?
28
Dividing a Future State Map
6 week forecast
30/ 60/ 90 day forecast
Production Planning
Supplier loop
Daily expedite
16 pieces/ day

• 320 pieces/ month
• 200 A1
• 120 A2

MRP
500 ft coils
Takt 2(480-20)minutes 57.5 mins
16 pieces Pitch 57.5 mins x 1 pieces
57.5 mins
2 shifts
Daily
Pitch 57.5 mins
Pack size 1
Daily Shipping plan
1
OOXXOOXX
batch
1
1
1
Pacemaker loop
Weld assy.
Stamping loop
Shipping
Stamping
TT 60 minute
stage
10 T
C/T55 min
delivery trays
2 days
1.5 days
3 x
1.5 days
SW C/O
5 days
166 minutes
2 days
1.5 days
1.5 days
165 min
1 min
Slug Brackets Stamping Currents State Map Date
.
29
Value Stream Mapping
AGENDA

• Introduction to mapping
• Creating a Current State Map
• Practical Exercise
• Introduction To Lean Techniques
• Creating a Future State Map
• Using a Map as a basis for Tactical
  Implementation Planning

30
Why Have a Formal Plan to Achieve the future
State?
To set the team direction
To show a relevant level of detail to those
concerned - NB. each loop will have its own
execution schedules within the implementation plan
To encourage regular reviews for signs of QCD
problems - slippage's, early deliveries,
continued ownership
To formalise commitment from key
people Facility Manager Value stream
manager The Unions Manufacturing
Engineering Maintenance Process
Engineering Purchasing
The key elements of a Value Streams
Implementation plan are shown in the following
example.
31
Example - Tactical Implementation Plan (T.I.P.)
Type of TIP and Model Line
5C Activity
TIP Owner
Timebased Schedule of activities
Category
32
Summary

• Collect data across a value stream.
• Use the 7 steps to draw a current state Value
  Stream Map.
• Use the 9 questions and 7 steps to draw a future
  state Value Stream Map.
• Identify your Material/Information loops.
• Decide the order to tackle the loops.
• Write the Tactical Implementation Plan
• Set objectives for each loop as required to
  achieve the future state
• Set measurable goals for each objective
• Use the 9 questions within each loop to set an
  order of work
• Set milestones and write up the plan
• Get formal agreement from all concerned
• The leader of each work stream should produce
  their own execution schedule showing how to
  achieve each goal by its milestone.

33
Value Stream Mapping
AGENDA

• Introduction to mapping
• Creating a Current State Map
• Practical Exercise
• Introduction To Lean Techniques
• Creating a Future State Map
• Using a Map as a basis for Tactical
  Implementation Planning

34
Summary
Just do it !