VALUE STREAM MAPPING

WHAT IS VALUE STREAM MAPPING? DESCRIPTION The Value Stream Mapping method (VSM) is a visualization tool oriented to the Toyota version of Lean Manufacturing (Toyota Production System). It helps to understand and streamline work processes by using the tools and techniques of Lean Manufacturing. The goal of VSM is to identify, to demonstrate and to decrease waste in the process. Waste is defined as any activity that does not add value to the final product. The word is often used to demonstrate and decrease the amount of "waste" in a manufacturing system. VSM can thus serve as a starting point to help management, engineers, production associates, schedulers, suppliers, and customers to recognize waste and identify its causes. As a result, Value Stream Mapping is primarily a communication tool, but it can also be used as a strategic planning tool. And as a change management tool. In order to do this, the Value Stream Mapping method visually maps the flow of materials and information. From the moment that the products are entering the back door as raw materials. Via all manufacturing process steps. Until the moment that the products leave the loading dock as finished products. Mapping out the activities in the manufacturing process with cycle times, down times, in-process inventory, material moves, information flows, helps to visualize the current state of the process activities and guides towards the future desired state. The process usually includes mapping the "Current State" and the "Future State". These then serve as the foundation for other Lean Manufacturing strategies. HISTORY OF VALUE STREAM MAPPING The use of waste removal to achieve competitive advantage inside organizations, was pioneered in the 1980s by Toyota's chief engineer, Taiichi Ohno, and sensei Shigeo Shingo and is oriented fundamentally towards productivity rather than towards quality. The reason for this is thought to be that improved productivity leads to leaner operations which help to expose further waste and quality problems in the system. Thus the systematic

attack on waste is also a systematic assault on the factors that are underlying poor quality. And on fundamental management problems. The seven commonly accepted wastes in the Toyota production system were originally (reformulation by Jones between brackets): 1. Overproduction (faster than necessary pace). 2. Waiting. 3. Transport (conveyance). 4. Inappropriate processing. 5. Unnecessary inventory (excess inventory). 6. Unnecessary motion. 7. Defects (correction of mistakes). Peter Hines and Nick Rich have suggested the following tools (Article: "The seven value stream mapping tools" International Journal of Operations & Production Management, Vol. 17, No. 1, 1997, pp. 46-64.). SEVEN VALUE STREAM MAPPING TOOLS 1. Process activity mapping. Origin: Industrial Engineering. 2. Supply chain response matrix. Origin: Time compression/logistics. 3. Production variety funnel. Origin: Operations Management. 4. Quality filter mapping. 5. Demand amplification mapping. Origin: Systems Dynamics. 6. Decision point analysis. Origin: Efficient Consumer Response/logistics. 7. Physical structure mapping. .

VALUE STREAM MAPPING FORUM Harshada - Indi Value Stream a Mapping Training Jason M - USA Value Stream for Design Engineering and PMI Recent User Comments "Is there any training program to implement VSM in any organization? Preferably VSM in Automobile Industry..." 0

"Hi everyone, I use a value stream process for design engineering that also works in conjunction with PMI's project management principles. For those who aren't familiar with these principles, they incorporate "project" fundamentals that initiate, plan, execute, monitor & control & close a project. Through my value stream there are a set of requirements for each major phase. At least for the teams I manage, this seems to be a good process for the design engineers to follow." Michael Value Stream "Hi, I'm currently looking in to the "cost and benefits" of Lundgren - Swe Management in implementing value stream management in a global IT den IT Services function. We have gone through a period of cost cutting and have further needs to reduce cost. Hence value stream management seems like a potential approach. I'm looking for companies (preferably in the service sector) that are using VSM to discuss experiencies. Appreciate your comments." Bernie - USA Changes in "Note that the realization of the action plan in VSM Behavior typically requires changes in activities and processes,

Prakash Saitwal - India

Value Stream Mapping Software

but may also require changes in behavior." "In what way will a software program help with value stream mapping? What are the criteria of selecting the most suitable software program. Please provide help in getting answers to these problem."

Prakash Saitwal - India

Defining Value "I am in process of implementing "value stream mapping" Stream as a tool to serve industries. I am facing constraints in the Mapping Areas implementation. After documenting the process under review and charting the present value stream, what is the process to identify the areas having least value addition and are on highest priority of value stream optimization." Dana Mappping "Hi everybody, I would need an advice concerning the Kristova - Czec Outsourced mapping of an outsourced activity in the production of h Republic Activities in one company where I'm working on my thesis. I haven't VSM found any information about how to map the value stream when the production isn't all done in one company. In my case, the original company starts to work on the product and because it's the smaller one, the product is then transported to another company which has the needed equipment for the operation needed. Then the product is transported back to the original company. I would like to know how to map this flow. If you have any experience with some similar case or if you have any ideas concerning how to map this, I would be very grateful for them. Thanks for your comments!" Van The Idea "Basically VSM is done to map the set of operations, Hooijdonk - The Behind Lean required for a product to launch from order to delivery to Netherlands VSM the market, considering both value-added and non value added operations. This mapping method is often used in lean transformations to find and eliminate waste in the value stream. A lean transformation can be compared to a river stream, in which you want your boat (the product) to flow without getting stuck on rocks (problem causers). To ease the flow, the water level (stock level, lead time) could be increased; the boat will not get stuck. Though it would create a rough stream (high costs) and eventually even abandonment of the ship (rejected sales). Better is to keep a minimum water level (lean) and to clear all the rocks (uncertainty, unreliability, scarcity and more) in the stream. VSM is used to constantly identify the rocks, clear them, and lower the water level again." Juan VSM Plan "I need to compare a VSM plan example. Please share a Cruz - Mexico Example case if you can." Farooq Omar 4 VSM Phases "The 4 Phases in VSM are: Pakistan 1. Current State Map of material flow and activities 2. Future State Map 3. Action Plan

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harshil - INDIA VSM in a job shop

4. Implementation" Best User Comments "I am currently working in a company where I have been told to implement VSM. But the problem is that its manufacturing activities are like a job shop and there is no repeatability.. Is VSM possible in this environment??" "Always remember to use "Common Sense " in your VSM." "I am currently in the process of mapping the supply chain within our facility. Having read both Value Stream Mapping (Tapping, Luyster & Shuker) and Learning to See (Rother & Shock) I should be focusing on a product family to assess the value and the waste rather than the overall material flow within the said process. What I wish to capture is the waste within the logistics support functions. For example good receipt into store and engine dispatch from store rather than the flow of material throughout the internal process. Any ideas in the right direction would be greatly appreciated."

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Joe VSM in general O'Brien - US James - Richard VSM within s Logistics Operations

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Reproduced form a live webinar for the audience to give them a better creative tool to open directional mindset. Autorization : Farooq Omar. International Executive Fast Track Association., USA Course coach : Mr. Hussanain Javed