Lean Manufacturing -

Value Stream Mapping

Wenqin Shao, MBA, P.Eng.

President
Sino Waypoint Consulting Inc.
shaow@siwyc.com

 Sino Waypoint Consulting Inc.

1
 Lean Manufacturing
• The Fundamental Insight & Objective

• Shift the focus of management from

existing organization, technologies, and
assets to the product!

• Differentiate value from waste

• Enhance value and remove waste by

looking down, not up!!!

 Sino Waypoint Consulting Inc.

2
 Summary
• Accurately specify value by product

• Identify the value stream

• Make the product flow

• At the pull of the customers

• In pursuit of perfection

 Sino Waypoint Consulting Inc.

3
 Benefits
• Dramatically reduce costs of manufacture

• Improving labour utilization;

• Decreasing inventories;

• Reducing manufacturing cycle times

(from order receipt to shipment);

• Increasing capacities without capital

expenditure.

 Sino Waypoint Consulting Inc.

4
 Achievements Improvements in direct &
indirect labour utilization

Increases in capacity in
current facilities 10%
10%&&50%
50%up
up

30%
30%&&up
up
50%
50%or
orgreater
greater Lean
Lean
Manufacturing
Manufacturing Improvement
productivity

70%
70%or
ormore
more 50%
50%or
orgreater
greater
Decreases in
manufacturing cycle Reductions in
times inventories

 Sino Waypoint Consulting Inc.

5
 Major Process Steps
Next Steps Of
VSM Practice

Implementing The
Future VSM Process

Mapping A Future
Value Stream Process

Begin By Mapping
The Existing Processes
Value Stream
Mapping
Self Assess Current
Manufacturing Process

 Sino Waypoint Consulting Inc.

6
 Assessment Radar Chart

1. Operation Strategy
2. Layout & Material
Handling
3. Quality Control
4. Visual Management
5. Team Approach
6. Staff flexibility
7. Cells and lines
8. Processes
9. Inventory
10.Setup
11.Maintenance
12.Suppliers

 Sino Waypoint Consulting Inc.

7
 Implementing Process
1. Begin by mapping the existing
processes
2. Segment products into families
3. Using process flow chart
4. Review material handling process
5. A great deal of discipline of instill in the
cell team
6. An effective lean design utilizes a high
level of visual control
7. Select and use measures to gauge
project results
8. Implement the project using tracking
tools.
 Sino Waypoint Consulting Inc.
8
Five Major Work Steps
Results
Evaluation
Reconfiguration
& Implementation

Create a future
Value Stream Map

Mapping
current process

VSM
process train

 Sino Waypoint Consulting Inc.

9
 The VSM Team
Project Sponsor
Project
Project
Sponsor
Sponsor

VSM
VSMteam
team
Coordinators
Coordinators

 Sino Waypoint Consulting Inc.

10
 VSM Timing

Elapsed Days
Major Worksteps
1 2 3 4 5 6 7 8
1. Participate in extensive Lean Manufacturing
training session
2. Principal of Lean Manufacturing Theory and
one piece flow concepts
3. Mapping current manufacturing process
4. Review process flow, create Future Value
Stream Map
5. Workcell Design and Lean Manufacturing
plant layout design
6. Reassessment and evaluation achievements

 Sino Waypoint Consulting Inc.

11
 A Results VSM

w Interpret results

w Apply the conclusions

w Provide greater insights

w Discuss implications

w Identify key areas of

improvement opportunity

 Sino Waypoint Consulting Inc.

12
 Lean Manufacturing Grid
Company’s
High Key Drivers Score
Value
World w Operation Strategy 1
1
Value Class w Layout and Material Handling
w Visual Management 2
“Value-added to
w Team Approach 1
eliminate waste”
w Setup 2
Company w Suppliers 2
Total Score 9/30
Efficiency
w Cells and Lines 3
w Quality Control 4
Low Efficiency High
w Staff Flexibility 2
“Leveraging process to
streamline operations” w Processes 5
w Inventory 3
w Maintenance 4
Total Score 21/30
 Sino Waypoint Consulting Inc.
13
Managing Toward Perfection
Next Future State

Future State

Current State Original State

 Sino Waypoint Consulting Inc.

14
 Practices & Opportunities

Annual Best Practices Conference

 Sino Waypoint Consulting Inc.

15
 Consulting Packages
One day package
• Principles & Lean Strategy
Current Process Assessment
The Lean Practice
Lean Strategy Development
Two days package (include day one package)
• Current Manufacturing Map
Kanban Design
Lean Scheduling
Cycle Counting
Rapid Setup
Five days package (include day one and two package)
• Future Value Stream Map
Lean Process Layout
Workcell Design
Future value stream map practice
Special Consulting package
• Kaizen blitz / 5S / Team building / Pull system
 Sino Waypoint Consulting Inc.
16
 Contact Information

Lean Manufacturing consulting Project

Contact:

Wenqin Shao
shaow@siwyc.com

 Sino Waypoint Consulting Inc.

17