LEAN

MANUFACTURING
Module-2
1
POM04
Value Stream Mapping

A very powerful tool for implementing the lean
transformation process is Value Stream Mapping (VSM).

Value stream mapping is a pencil and paper tool that
helps you to see and understand the flow of material and
information as a product makes its way through the value
stream.

A value stream is all the actions (both value added and
non-value added) currently required to bring a product
through the main flows essential to every product.


2
Value Stream Mapping
Current State Map
Follow a products production path from customer to supplier,
and carefully draw a visual representation of every process in
the material and information flow.

Future State Map
Ask a set of key questions and draw the map of how value
should flow in the future (desired flow).


3
Value Stream Mapping


4
Value Stream Mapping


5
Steps
Select one value stream - a product family
Walk the physical flow of material no data collection
Walk the flow again, collecting data
Draw the Current State Map
Identify opportunities to eliminate waste and create flow
Draw the Future State Map
Generate a Value Stream Plan
Start making the improvements
Conduct Value Stream Reviews
Repeat the cycle
Selecting a Product Family


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A Product Family
A family is group of products that pass through similar processing
steps and over common equipment in the downstream process and
have similar work contents.
Value Stream Mapping Icons
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Value Stream Mapping Icons
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Value Stream Mapping Icons
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Terms one should know before
mapping
10
Customer Need
Demand : Number of units per day the customer wants.

Available Working Time: Scheduled working time minus breaks
,meeting and clean up time
Inventory
WIP : Number of units waiting to be worked on or waiting to be
moved.

Finished: Number of units in stores or waiting to be shipped .
Terms one should know before
mapping
11
Each Process Step
Cycle Time : The time between one part coming off the process
and the next part coming off.

Number of people: Required to operate the process

Uptime: The percentage of time the equipment is available to run
,when it is needed to run

Batch Size: Typical lot size or minimum.

Change Over Time: The time from the last good piece of one
batch to the first good piece of the next batch.

EPE..Every part every ____ .How often do you changeover to
produce this part.

Terms one should know before
mapping
12
Each Process Step
Takt Time TT : Available time per day/demand per day.

Inventory(Measured in days) = Number of units /demand
per day



Overall Flow
Process Lead Time : The time for a unit to make all the way through the
process (Sum of Inventory days + Sum of Cycle times).
Processing Time: The time actually spent performing work on the unit
(Sum of Cycle times)
13
ACME STAMPING CASE
STUDY
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Whats wrong with Acmes Value
Stream?
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Traditional mass production thinking about economies of
scale
Batches pushed through = Waste
Look at VA time compared to time in plant