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Gaurav Narula
By : Gaurav Narula
Lean Implementation
Why do Value Stream Mapping?
Implementation without a plan will lead to disaster
Customer
Weekly Order Rolling 6-wk For Xstpcs/ month
eca
6-wk forecast Std Pack Qty
Steel Supplier PC & L # Shifts
Level Box
DA1
Layout
Finished Goods
.Time? days
Inv ? days ? days ? days TPc
/t = ?
.Time
Proc ? days ? days ? days
Eyes for Waste . . .
. . . Eyes for Flow
By : Gaurav Narula
3
Objectives
Explain Value Stream Mapping
Complete a Current State Value
Stream Map
Complete a Future State Value Stream
Map with proposed Implementation
Plan
By : Gaurav Narula
Agenda
Introduction to Value Stream Mapping
Current State Map Session
1
Data Collection
Activity: Map Current State
Review Current State Map
Design Future State
Future State Map
Session
Consider Key Questions 2
Summary
Activity: Design Future State
By : Gaurav Narula
Agenda - Session 1
Introduction to Value Stream Mapping
Data Collection
By : Gaurav Narula
Introduction to Value Stream Mapping
Definition of Value Stream
Raw Finished
Material Product
DA1
Daily DA2
DA3
6 x / Day
Layout
AND...
Eliminate Waste
By : Gaurav Narula
1
Introduction to Value Stream Mapping
The Process
# times/day
Layout
and
WIP = WIP =
Training
By : Gaurav Narula
4
Agenda - Session 1
Introduction to Value Stream Mapping
Data Collection
By : Gaurav Narula
Current State Map
The Steps
By : Gaurav Narula
Current State Map
Step 1: Select a Value Stream (Product Family)
By : Gaurav Narula
Current State
Step 2: Form a Team
◆ Production Control
Demand/month:
Part A =
Part B =
(monthly/weekly forecasts)
Part C =
# of shifts =
By : Gaurav Narula
1
Current State Map
Customer
Demand/month:
Part A =
Part B =
Part C =
# of shifts =
Changeover
Downtime FTQ
By : Gaurav Narula
Current State Map
Step 5: Map the Material Flow
Customer
Supplier
Demand/month:
Part A =
Part B =
Part C =
# of shifts =
2 x/ 2 x/
week day
Shipping
Stamping Welding Assembly
I I I I
1,200 pcs 1,500 pcs 800 pcs 500 pcs
Takt = Takt = Takt = Inventory
C.T. = C.T. = C.T. = Part A =
D.T. = D.T. = 20% D.T. = Part B =
FTQ = FTQ = FTQ = 90% Part C =
C/O Time = 4 hrs. C/O Time = C/O Time = # of shifts =
Lot Size = Lot Size = Lot Size =
# of Shifts # of Shifts # of Shifts
WIP = WIP = WIP =
2 x/
week 2 x/
day
I I I I
1,200 pcs 1,500 pcs 800 pcs 500 pcs
Takt = Takt = Takt = Inventory
C.T. = C.T. = C.T. = Part A = 750 pcs
D.T. = D.T. = 20% D.T. = Part B = 600 pcs
FTQ = FTQ = FTQ = 90% Part C = 1650 pcs
C/O Time = 4 hrs. C/O Time = C/O Time = # of shifts =
Lot Size = Lot Size = Lot Size =
# of Shifts # of Shifts # of Shifts
WIP = 25 pcs. WIP = 60 pcs. WIP = 550 pcs.
By : Gaurav Narula
Changeover Downtime FTQ
Step 7: Calculate Total Product Cycle Time
PC & L
6 week rolling forecast
Weekly Order
6 week rolling forecast
Weekly Order Customer
Daily Ship Schedule
Supplier
Demand/month:
Part A = 705 pcs.
Weekly Build Schedule
Part B = 600 pcs.
Part C = 1650 pcs.
# of shifts =
2 x/ 2 x/
week day
I I I
800 pcs I
1,200 pcs 1,500 pcs 500 pcs
Takt = Takt = Takt = Inventory
C.T. = C.T. = C.T. = Part A = 750 pcs
D.T. = D.T. = 20% D.T. = Part B = 600 pcs
FTQ = FTQ = FTQ = 90% Part C = 1650 pcs
C/O Time = 4 hrs. C/O Time = C/O Time = # of shifts =
Lot Size = Lot Size = Lot Size =
# of Shifts # of Shifts # of Shifts
WIP = 25 pcs. WIP = 60 pcs. WIP = 550 pcs.
Press Room
Fork Truck
Die Bench
Die Room Die Room
Receiving Shipping
(Remove from
Schedule
I I Board)
Dies Dies
12 shifts 2 shifts
Schedule Board
(Forecast)
By : Gaurav Narula
Current State Map
Additional Mapping Icons
Kanban Kanban
Supermarket
Path Post
Signal Kanban
Kanban arriving MAX 50 PCS
First-In
in batches FIFO First-Out
Flow
Withdrawal
Physical
Kanban
Pull
Production Process
Leveling Kaizen
Kanban
By : Gaurav Narula
Data Collection
Data Collection
By : Gaurav Narula
Data Collection
Attribute Data to Collect
Shipping/Receiving Work-in-process
schedules inventory
Pack sizes at each Overtime per week
process
Demand rates by Process cycle times
process (Takt Time) Number of product
Working hours and variations at each step
breaks
Scrap Batch (lot) sizes
Inventory Points
(location & size) Rework
Changeover times
How Operations are Changeover
Downtime
scheduled frequencies
By : Gaurav Narula
Data Collection
Data Box
Tailor the
data box for
your plant’s
o x
needs.
a B
a t The data
D box should
be open
ended to
allow for
additional
attributes.
By : Gaurav Narula
Introduction to Value Stream Mapping
Tools
Scrap
Manufacturing Kaizen
Process Lightning
Burst
Outside
Buffer or
Source/
Safety Stock
Customer
Manual
Information Flow
Data Box
Electronic
I Information Flow
Inventory
Production Kanban
oTruck
oo
Shipment
Withdrawal Kanban
Finished
Goods to Customer
By : Gaurav Narula
Data Collection
What is Takt Time?
Your Operating Time per Shift
Customer Requirement per Shift
27,000 sec
460pieces = 59sec 59 sec.
59 sec.
59 sec.
By : Gaurav Narula
1
Data Collection
How to Calculate Takt Time?
Scheduled Runtime
Takt Time =
Total Customer Requirements
By : Gaurav Narula
3
Data Collection
Identify Opportunities for Improvement
?
By : Gaurav Narula
Agenda - Session 1
Introduction to Value Stream Mapping
Data Collection
By : Gaurav Narula
Activity: Map the Current State
Approximate
Complete By Task Total Time:
By : Gaurav Narula
Session 2
Agenda
Review current state
Over view of developing future state
Develop future state
Develop action plans to get to future state
Assign owners, timing, and frequency of review for action
items
Report to leadership
Support
Learning
By : Gaurav Narula
Agenda - Session 2
Review Current State Map
Summary
• Summary
Change I
Over
2
Sender
Ass’y
2 I 2 Level
I Fuel Pump No Flow 2
Ass’y I Inj: Sender ABABA. . .
Molding Ass’y
Attendance Labels Staging
by Truck
10 Tank 4 Ass’y
Stamping I Ass’y Plants 10
Tank 4 Ass’y
Stamping Ass’y card Plants
No Flow
by
Change
Over 12 card
Uptime
7
(Pitch = 14 Units)
Cycle-Time Driven. Batches. Perform to TAKT & Pitch. Zone Maintenance & Fast Response
Produce to Order
METRICS Activity
1999 2000
1ST 2ND 3RD 4TH 1ST 2ND 3RD 4TH
Item Current Target
Establish TAKT & Flow in Tank Ass'y
Total product cycle time
Stamping Changeover Reduction
Parts / Person Hour Reduce Stamping Buffer
Delivery Performance Move Ass'y to Plant 10
Establish TAKT & Flow in Sender Ass'y
Inventory (days)
Pull To Sender Ass'y
Overtime
Uptime Training
By : Gaurav Narula
Future State Map
The Steps
“Do It”
Implement - Implement - Implement
A simple way to
approach the Future
State Map is to begin
by modifying the
Current State Map.
By : Gaurav Narula
Agenda - Session 2
Review Current State Map
Summary
How will you level the production mix at the pacemaker process?
What increment of work will you consistently release
and take away at the pacemaker process?
What process improvements will be necessary at the value
stream to flow as your future state design specifies?
By : Gaurav Narula
Consider Key Questions
Will you build to a finished goods supermarket
or directly to shipping?
The Wall
of Protection:
Batch Process
Process
I Process
I Process
“A” “B” “C” Elapsed Time:
60 Minutes
By : Gaurav Narula
3
Consider Key Questions
Where can you use continuous flow processing?
(Batch Process vs. Continuous Flow)
Batch Process
Process
I Process
I Process
“A” “B” “C”
Elapsed Time:
60 Minutes
FIFO
By : Gaurav Narula
2
Consider Key Questions
At what single point in the
PC&L production chain will you
schedule production?
Molding Assembly
FIFO
By : Gaurav Narula
1 Pacemaker Process
Consider Key Questions
How will you level the production mix at the pacemaker process?
Consideration must be given to level both the mix and overall quantity of
product scheduled for production.
Leveling of the production schedule is a fundamental requirement for the
efficient management of operations
Work- Work-
load load
Time Time
By : Gaurav Narula
2
Consider Key Questions
How will you level the production mix at the pacemaker process?
(Continued)
Leveling of the overall production quantity must be supported by the
leveling of the product mix.
Part A & B
Mon. Tue. Wed. Thu . Fri.
Mon. Tue. Wed. Thu. Fri.
By : Gaurav Narula
2
Consider Key Questions
How will you level the production mix at the pacemaker process?
(Continued)
Leveling
of the product mix must be
supported by small lot production.
Smalllot production must be supported by
quick set-up.
By : Gaurav Narula
Consider Key Questions
How will you level the production mix at the pacemaker process?
(Continued)
An effective way
of communicating
the level schedule
to manufacturing
operations can be
through the use of
a load leveling
box.
By : Gaurav Narula
Consider Key Questions
What increment of work will you consistently
release and take away at the pacemaker process?
Macro-Leveling
Mon Tues Wed Thurs Fri Sat Sun
Part
Build
A
Order
Part
B
Part
C
Part
D
Part
E
By : Gaurav Narula
Consider Key Questions
What increment of work will you consistently
release and take away at the pacemaker process?
(Continued)
Micro-Leveling
Build Order
Sequenced and Timed
Part
Card (Part A)
Card (Part A)
Card (Part A)
A
Part
Card (Part B)
Card (Part B)
Card (Part B)
Part
Card (Part C)
Card (Part C)
Card (Part B)
C
By : Gaurav Narula
Agenda - Session 2
Review Current State Map
Summary
By : Gaurav Narula
Agenda - Session 2
Review Current State Map
Summary
By : Gaurav Narula