value stream mapping an overview

8/13/2019 Value Stream Mapping an Overview

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Value-Stream Mapping to Create Value and Eliminate

Muda

Presentedby

Mohammed El BoussamiHafez Shurrab


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Introduction

Value Stream

Mapping

Seven wastes

Supply Chain


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Why Value Stream Mapping Information & materials relation Identify Wastes Continuous Improvement


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Five Steps to do Value Stream Mapping

Product Family

Current State Map

Future State Map

Plan

Value Stream Map


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CASE STUDY: ACME STAMPING & WIRE

FORMING CO.

Acme has been incorporated in 1921

Metal Stamping, CNC Machining, & Wire Forming

Mass Prodcution & Push Systems

Lean Manucaturing & Pull Systems


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ProcessCycleTime(sec.)

Changeover Time(sec.)

Uptime( )

WIP next to the process

(unit), L: lift, R: right (D): Day of Demand

Stamping1 3600 85 4600 L - 2400 R 7.6 D

Welding 39 600 100 1100 L - 600 R 1.8 D

Welding 2 46 600 80 1600 L - 850 R 2.7 DAssembly

62 - 100 1200 L - 640 R 2 D

Assembly 240 - 100 2700 L - 1440 R 4.5 D

The data of Acme's Production Processes


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Current State Map


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Guiding Questions

What is the takt time of Acme for the selected product family?

Should Acme build steering brackets directly to shipping or to a finished goods supermarket/buffer?

Where could continuous flow be introduced?

Where buffers would be set?

What the pacemaker process?

How should Acme level the production mix?

What consistent increment of work should be released?

What process improvements will be necessary?


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Load-Leveling Box

shift 1 7 720 740 8 820 840 910 930

shift 2 4 420 440 5 520 540 610 630

Left Drive L L L L L

Right Drive R R R


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Future State Map


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Acme Stamping Lead-Time Improvement

Location Coil Stamped Parts Wie/Ass. WIPFinishedGoods

Production LeadTime

Total InventoryTurns

Before 5 Days 7.5 Days 6.5 Days 4.5 Days 23.6 Days 10

Continuous Flow &Pull 2 Days 1.5 Days 0 4.5 Days 8 Days 30

With Leveling 1.5 Days 1 Day 0 2 Days 4.5 Days 53


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Conclusion

VSM is highly recommended tool to eliminate muda.

There should be high cooperation between all business owners in the supply chain.

VSM guides to which tools and practices could be effeciently incorporated.

Kaizen targets should be given high priorities.

VSM could be also helpful for intelligent benchmarking.


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Conclusion (cont.)

Some concerns are:

The diversity of indusries characteristics

Technological limits

Resistance to change

The accessibility of data


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value stream mapping an overview

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