introduction to mapping creating a current state map introduction to lean techniques creating a...

Introduction to mapping

Creating a Current State Map

Introduction To Lean Techniques

Creating a Future State Map

Using a Map as a basis for Tactical Implementation Planning

AGENDA

Value Stream Mapping

1. What are the customer requirements

2. How to apply Continuous Flow Processing

3. Which process is the pacemaker

4. How to control upstream processes

5. What size supermarkets (shop stock) are required

6. Is it sequential or fill-up pull

7. Where to level production

8. At what frequency will kanban be released

9. What further improvements can be made

THE 9 KEY QUESTIONS :

Future State Value Stream Mapping

THE 7 STEPS

1. Customer Requirements

2. Draw Process Steps

3. Process Data

4. Inventory

5. Material Flow: Supplier to Manufacturer & Manufacturer to Customer

6. Information Driving Flow & Internal Material Flow

7. Manufacturing Lead Time & Processing Time

Creating a Future State Value Stream Map

Ref.ppt

FIFO

abc

Production Control

I

OXOX 44

4

Supermarket

Supermarketwith Prod Card

Supermarket with Prod Card & Withdrawal card

First In First Out sequence flow

Kanban Post

Inventory

Pull Symbol

Information System VSM Symbols

Production Control

Electronic information flow Level loading Production

Signal KanbanMin & Max

Manual Information flow

Kaizen lightening burst

Truck Shipment

Mon + Wed

PUSH arrow

300 pieces 1Day

CHANGEOVER

XYZ corporation

Outside sources

Sequenced-Pull Ball

Icons for use in Future State

Customer

.

Pack size = 1

320 pieces/ month•200 A1•120 A2

2 shifts

Shipping Assembly # 2Assembly # 1Spot weld # 2Spot weld # 1Stamping

Cycle time= 1 minute

Change over=1 hour

Uptime =85%

1 x


Change over=10 min.

Uptime =100%

1 x

10 T


Change over=10 min.

Uptime =80%

1 x


Change over=0 min.

Uptime =100%

1 x


Change over=0 min.

Uptime =100%

1 x

II I I5 days 150 A1

24 A2

I I42 A16 A2

16 A118 A2

42 A16 A2

27 A114 A2

Coils r us

500 ft coils

Tuesdayand

Thursday

Production Planning

30/ 60/ 90 day forecast

Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day

10.9 days 2.1 days 3 days 2.6 days5 days

Production Lead Time = 26.6 days

Processing time = 188 mins

1 minute 39 minute 46 minute 62 minute 40 minute

3 days

Current State Map

Slug Brackets StampingCurrents State Map Date :

1 x Daily

Customer

.

Pack size = 1


2 shifts



Change over=1 hour

Uptime =85%

1 x


Change over=10 min.

Uptime =100%

1 x

10 T


Change over=10 min.

Uptime =80%

1 x


Change over=0 min.

Uptime =100%

1 x


Change over=0 min.

Uptime =100%

1 x

II I I5 days 150 A1

24 A2

I I42 A16 A2

16 A18 A2

42 A16 A2

27 A114 A2

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day

10.9 days 3 days 2.1 days 3 days 2.6 days5 days



Takt = 2(480-20)minutes = 57.5 mins 16 pieces

Pitch = 57.5 mins x 1 pieces = 57.5 mins

x

1 minute 39 minute 46 minute 62 minute 40 minute

Coils r us

Add Takt Calculation


1 x Daily

Stamp SW 1 SW 2 Assy. 1 Assy. 2

1 min.

39 min.

46 min.

62 min.

40 min.

57.5 min.Takt

DRAW ON FLIP CHART

Where is Continuous Flow Possible?

Customer

.

Pack size = 1


2 shifts



Change over=1 hour

Uptime =85%

1 x


Change over=10 min.

Uptime =100%

1 x

10 T


Change over=10 min.

Uptime =80%

1 x


Change over=0 min.

Uptime =100%

1 x


Change over=0 min.

Uptime =100%

1 x

II I I5 days 150 A1

24 A2

I I200 A16 A2

16 A18 A2

42 A16 A2

27 A114 A2

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day






Coils r us

Drawing a Future State Map


1 x Daily


1 min.

39 min.

46 min.

62 min.

40 min.

DRAW ON FLIP CHART

57.5 min.Takt


Customer

.

Pack size = 1


2 shifts



Change over=1 hour

Uptime =85%

1 x


Change over=10 min.

Uptime =100%

1 x

10 T


Change over=10 min.

Uptime =80%

1 x


Change over=0 min.

Uptime =100%

1 x


Change over=0 min.

Uptime =100%

1 x

II I I5 days 150 A1

24 A2

I I200 A16 A2

16 A18 A2

42 A16 A2

27 A114 A2

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day






Coils r us



1 x Daily


1 min.

39 min.46 min.

62 min.

40 min.

DRAW ON FLIP CHART

57.5 min.Takt


Customer

.

Pack size = 1


2 shifts



Change over=1 hour

Uptime =85%

1 x


Change over=10 min.

Uptime =100%

1 x

10 T


Change over=10 min.

Uptime =80%

1 x


Change over=0 min.

Uptime =100%

1 x


Change over=0 min.

Uptime =100%

1 x

II I I5 days 150 A1

24 A2

I I200 A16 A2

16 A18 A2

42 A16 A2

27 A114 A2

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day






Coils r us



1 x Daily

x

Ideal No. Of Operators = Total Work Content Takt Time

e.g.

Ideal No. Of Operators = 187 minutes of work 57.5 minutes Takt

= 3.25 operators

= 4

= target of 3


55 55 55

(55 X 3) + 22 = 187 minutes

DRAW ON FLIP CHART

Takt

Cycle Time

Stamp

1 min.SW 1

SW 2

Assy. 1

Assy. 2

39 min.

SW 2

30 min.

16 min.

25 min.

Assy. 1

37 min.

18 min.

Assy. 2

22 min.

57.5 min.Takt


Customer

.

Pack size = 1


2 shifts



Change over=1 hour

Uptime =85%

1 x


Change over=10 min.

Uptime =100%

1 x

10 T


Change over=10 min.

Uptime =80%

1 x


Change over=0 min.

Uptime =100%

1 x


Change over=0 min.

Uptime =100%

1 x

II I I5 days 150 A1

24 A2

I I200 A16 A2

16 A18 A2

42 A16 A2

27 A114 A2

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day






Coils r us



1 x Daily

Customer

.

Pack size = 1


2 shifts

Shipping Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

I5 days

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day

Work contentTo 55 min.

SW C/OSW 2uptime

2 days

Weld+ assy.



Target 3 Ops

Coils r us



1 x Daily

Customer

.

Pack size = 1


2 shifts

Shipping Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

I5 days

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1

Weld+ assy.



Target 3 Ops

Coils r us



1 x Daily

Customer

.

Pack size = 1


2 shifts

Shipping Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

I5 days

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1

1

Weld+ assy.



Target 3 Ops



1 x Daily

Customer

.

Pack size = 1


2 shifts

Shipping Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

I5 days

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1batch

Weld+ assy.



Target 3 Ops

Coils r us



1 x Daily

Customer

.

Pack size = 1


2 shifts

Shipping Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

I5 days

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

Dailyshipping

plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1batch

1.5 days delivery trays

Weld+ assy.



Target 3 Ops

Coils r us



1 x Daily

11

Customer

.

Pack size = 1


2 shifts

Shipping

Weld+ assy.

Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

I5 days

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

DailyShipping plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1batch

1.5 days

1

stage delivery trays



Target 3 Ops

Coils r us



1 x Daily

11

Customer

.

Pack size = 1


2 shifts

Shipping

Weld+ assy.

Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

I5 days

500 ft coils

Tuesdayand

Thursday

Production Planning


Daily expedite

6 week forecast

Weekly fax

MRP

Weekly plan

DailyShipping plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1batch

1.5 days

1

stage

OOXXOOXX

Pitch = 57.5 mins

delivery trays

1

2

34



Target 3 Ops

Coils r us



1 x Daily

11

Customer

.

Pack size = 1


2 shifts

Shipping

Weld+ assy.

Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

500 ft coils

Daily

Production Planning


Daily expedite

6 week forecast

MRP

Weekly plan

DailyShipping plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1batch

1.5 days

1

stage

OOXXOOXX

Pitch = 57.5mins

1.5days

delivery trays



Target 3 Ops

Coils r us



1 x Daily

11

Customer

.

Pack size = 1


2 shifts

Shipping

Weld+ assy.

Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

4 x

500 ft coils

Daily

Production Planning


Daily expedite

6 week forecast

MRP

DailyShipping plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1batch

1.5 days

1

stage

OOXXOOXX

1.5days

1.5days 1 min

1.5 days165 min

2 days

5 days

166 minutes

delivery trays



Pitch = 57.5 mins

Target 3 Ops

Coils r us



1 x Daily

Delegates to design own future state map


Current State Map

Future State Map

GapAnalysis……………...

WHERE WILL YOU START ?

Developing an Improvement Plan

11

Customer

.

Pack size = 1


2 shifts

Shipping

Weld+ assy.

Stamping


Change over=1 hour

Uptime =85%

1 x

10 T

TT= 60 minute

C/T=55 min

3 x

F.A.L.

500 ft coils

Daily

Production Planning


Daily expedite

6 week forecast

MRP

DailyShipping plan

16 pieces/ day


SW C/OSW 2uptime

2 days

1batch

1.5 days

1

stage

OOXXOOXX

1.5days

1.5days 1 min

1.5 days165 min

2 days

5 days

166 minutes

Supplier loop

Stampingloop

Pacemaker loop

delivery trays



Pitch = 57.5 mins

Target 3 Ops

Dividing a Future State Map


1 x Daily



Practical Exercise




AGENDA


To set theteam

direction

To show a relevant level of detail to those concerned -NB. each loop will have it’s own execution schedules

within the implementation plan

To encourage regular reviews for signs of QCD problems -slippage's, early deliveries, continued ownership

To formalise commitment from key people:Facility Manager Value stream managerThe Unions Manufacturing EngineeringMaintenance Process Engineering

Purchasing

The key elements of a Value Stream’s Implementation planare shown in the following example.

Why Have a Formal Plan to Achieve the future State?

Example - Tactical Implementation Plan (T.I.P.)

5C Activity

Category

Level 1 Activity

Level 2DetailedActions

TimebasedSchedule of

activities

Type of TIPand Model Line

Responsible People

Collect data across a value stream.

Use the 7 steps to draw a current state Value Stream Map.

Use the 9 questions and 7 steps to draw a future state Value Stream Map.

Identify your Material/Information loops.

Decide the order to tackle the loops.

Write the Tactical Implementation Plan• Set objectives for each loop as required to achieve the future state• Set measurable goals for each objective• Use the 9 questions within each loop to set an order of work• Set milestones and write up the plan• Get formal agreement from all concerned

The leader of each work stream should produce their own execution schedule showing how to achieve each goal by it’s milestone.

Summary



Practical Exercise




AGENDA


Summary

Just do it !Just do it !

introduction to mapping creating a current state map introduction to lean techniques creating a...

Documents

minute change

stamping cycle time

days processing time

t cycle time

mins x

days production lead

hour uptime

daily slide