value stream mapping€¦ · value stream mapping icons information flow icons material flow icons...

1. Purpose of MIFC (Material Flow Chart; Value Stream Maps)

2. How to draw MIFC (how to grasp the current condition)

3. MIFC / VSM Examples

EDMM 4870

Value Stream Mapping

1

Value StreamMapping Icons

INFORMATIONFLOW ICONS

MATERIALFLOW ICONS

Press

ManufacturingProcess

Heat Treat

ManufacturingProcess Shared

XYZ Corp.

Outside Sources

C/T= 25

C/O= 40

2 Shifts

Takt= 1s

Data Box

Inventory Box

PUSH Arrow

Finished Goods to Customer

Supermarket

Physical Pull

Manual Info Flow

Electronic Info Flow

Weekly Schedule

Schedule

Withdrawal Kanban

Production Kanban

Load Leveling

Signal Kanban

Kanban Post

Sequenced Pull Ball

GENERALICONS

Kaizen Lightening Burst

Buffer or Safety Stock

First-In-First-OutSequence Flow

F I F O

Operator

Go See ProductionScheduling

Move byForklift

QQuality

Problem

2X perWeek

Truck Shipment

Boat Shipment



MATERIALFLOW ICONS

Press


Heat Treat


XYZ Corp.

Outside Sources

C/T= 25

C/O= 40

2 Shifts

Takt= 1s

Data Box

Inventory Box

PUSH Arrow


Supermarket

Physical Pull

Manual Info Flow


Weekly Schedule

Schedule

Withdrawal Kanban

Production Kanban

Load Leveling

Signal Kanban

Kanban Post

Sequenced Pull Ball

GENERALICONS




F I F O

Operator


Move byForklift

QQuality

Problem

2X perWeek

Truck Shipment

Boat Shipment



MATERIALFLOW ICONS

Press


Heat Treat


XYZ Corp.

Outside Sources

C/T= 25

C/O= 40

2 Shifts

Takt= 1s

Data Box

Inventory Box

PUSH Arrow


Supermarket

Physical Pull

Manual Info Flow


Weekly Schedule

Schedule

Withdrawal Kanban

Production Kanban

Load Leveling

Signal Kanban

Kanban Post

Sequenced Pull Ball

GENERALICONS




F I F O

Operator


Move byForklift

QQuality

Problem

2X perWeek

Truck Shipment

Boat Shipment



MATERIALFLOW ICONS

Press


Heat Treat


XYZ Corp.

Outside Sources

C/T= 25

C/O= 40

2 Shifts

Takt= 1s

Data Box

Inventory Box

PUSH Arrow


Supermarket

Physical Pull

Manual Info Flow


Weekly Schedule

Schedule

Withdrawal Kanban

Production Kanban

Load Leveling

Signal Kanban

Kanban Post

Sequenced Pull Ball

GENERALICONS




F I F O

Operator


Move byForklift

QQuality

Problem

2X perWeek

Truck Shipment

Boat Shipment



MATERIALFLOW ICONS

Press


Heat Treat


XYZ Corp.

Outside Sources

C/T= 25

C/O= 40

2 Shifts

Takt= 1s

Data Box

Inventory Box

PUSH Arrow


Supermarket

Physical Pull

Manual Info Flow


Weekly Schedule

Schedule

Withdrawal Kanban

Production Kanban

Load Leveling

Signal Kanban

Kanban Post

Sequenced Pull Ball

GENERALICONS




F I F O

Operator


Move byForklift

QQuality

Problem

2X perWeek

Truck Shipment

Boat Shipment

EDMM 4870

Common Value Stream / Material Information Chart Icons

2

Purpose of a VSM /MIFC

EDMM 4870

3

See current level of JIT - Problems (stagnation) on shop floor

Get Flow and Stagnation of Material and

Information from the Location (Gemba)

Do Kaizen to reduce

the problem

(stagnation)

Improve JIT = Lead Time reduction

Make Problem

Visible

See FUTURE

EDMM 4870

Use VSM /MIFC, to find problems quickly & show simply.

4

Rules to follow:

1. Start at the “End”, the Shipping Warehouse. (Follow the philosophy

of “Pull”)

2. Try to avoid asking team members questions to get your

answers….using the “Gemba” approach, you will learn better by

investigating and seeing and doing it yourself.

3. Ask yourself, “I wonder how this got here?”…and follow the

evidence backwards.

4. Use pencil and paper and be willing to keep making corrections.

5. Test what you have developed. “Go and see” on a different shift or

with different team members and determine if the flow remains the

same.

"Having no problems is the biggest problem of all.” – Taiichi Ohno

EDMM 4870

5

Example of a Material & Information Flow Chart

W

1-2-2

W

1-4-4

2 times/ Shift

（8:00,13:00）

2 times / Shift

（9:00,14:00）

引引

W仕I

仕I Lot Production

5 Kanban/lot

Parts withdrawal Kanban

Parts withdrawal Kanban

A Plant

B Plant

Lots

Product staging/

Shipping Area

Production instruction

Kanban

Assemble Line

Lead time 16Hr

Material Flow

Information Flow

What is moved?, When?, from Where to

Where?, When?, by Who?, How Much?, How

Moved?,

EDMM 4870

6

What is the proper attitude for performing a MIFC?

➢ “Always ask about the “parts” and “process”

➢ Clarify the need and the purpose?

Do not believe the information from people or documents / records

about the process unconditionally.

- (SEE with your own eyes)

- Confirm facts with Genchi Genbutsu: Go-See, Understand Deeply

- Sort out the problems with Genchi Genbutsu considering the need

and the purpose of Kaizen.

➢ Capture the Real condition, not how it is supposed to be.

- If your MIFC does not reflect the facts from the process it is

worthless.

- Use Symbols to simplify drawing (See Handout)

EDMM 4870

7

Some basic

symbols, How to

use

Can develop your own

symbols, but using

common symbols

makes Yoketen easier.

Key =

1. YOU can understand

(see) Material &

Information Flow.

2. OTHERS can

understand (see)

Material & Information

Flow from your chart.

3. Problems Exposed

Term Symbols Example Use/DescriptionDesignation of Information and Material Flow w ithin a Production System

Information Flow (This representation w ithout frequent pull)

Material Flow

Information (Electronic)

A Production Instruction Kanban is used to authorize the start of production

Production at a production process.

Instruction Kanban

A Parts Withdraw al Kanban indicates the timing and quantity for a Team

Parts member at one process to pickup a new supply of parts from a preceding

Withdrawal process.

Kanban

A type of Production Instruction Kanban used to inform that the reorder

Signal Kanban point has been reached and a part or material lot needs to be replaced.

Construction of production lots of predetermined sizes.

Lot

Making

Board / Box

Identif ies a centralized location w here kanbans are placed for pickup.

Kanban

Post Kanban Post

- sequenced

-or-

Kanban

Cycle X-Y-Z

withdrawl kanban Qty per day * (x) * (z+1)/y + Safety

calculation capacity per box

Customer

SupplierProduction

Control

Forecast Firm/Unf irm) Customer Order

3

Stamping

Paint

3

3

Paint

X - Delivery frequency in Days -(1 Day)

Y - Deliveries in "X" Days (8 Delivery cycles/Day)

Z - Delivery Delay after Kanban has been sent(Parts for this kanban w ill be delivered 4 cycles after

kanban sent)

1 - 8 - 4

3

Mold

3

Mold Assy.

3

3

Mold Assy.

3

3

Paint

Lot Making Board

I

W

EDMM 4870

8



Material Flow




Instruction Kanban



Withdrawal process.

Kanban




Lot

Making

Board / Box


Kanban

Post Kanban Post

- sequenced

-or-

Kanban

Cycle X-Y-Z



Customer

SupplierProduction

Control


3

Stamping

Paint

3

3

Paint




kanban sent)

1 - 8 - 4

3

Mold

3

Mold Assy.

3

3

Mold Assy.

3

3

Paint

Lot Making Board

I

W



Material Flow




Instruction Kanban



Withdrawal process.

Kanban




Lot

Making

Board / Box


Kanban

Post Kanban Post

- sequenced

-or-

Kanban

Cycle X-Y-Z



Customer

SupplierProduction

Control


3

Stamping

Paint

3

3

Paint




kanban sent)

1 - 8 - 4

3

Mold

3

Mold Assy.

3

3

Mold Assy.

3

3

Paint

Lot Making Board

I

W

Some basic symbols,

How to use

Can develop your own

symbols, but using

common symbols makes

Yoketen easier.

Key =

1. YOU can understand

(see) Material &

Information Flow.

2. OTHERS can

understand (see)

Material & Information

Flow from your chart.

3. Problems Exposed

EDMM 4870

9

Before Condition (Problem Identif ication)

Process

Characteristics

This symbol is used to show one for one (sequence) order is maintained.

Sequence

FIFO Material Flow

(First In --> First Out)

Production sequence

or - Delivery Seq.

plan

Tablet*

*Tool that is sent to beginning of process when product removed

and authorizes release of next product - controls total # in process

SIPS

Standard In Process

Stock

Mold

Long C/OTime=60'

1

ØØØØ

Ø

Ø

Auto

Weld

1

EDMM 4870

10

Identif ies outside Suppliers (Parts or Materials).

Supplier Parts or

Materials, or outside

Processing

Each block represents one process.

Manufacturing Designates:

Process 1 x 1 or 1 kanban X 1 kanban.

on Line Each block represents one process.

Designates:

Batch Production

Material or Information

Stagnation

no rule - random

Temporary Store

Store

Material or parts pushed to the next process or operation w ith no

Push reference to need.

Material

Flow

Material Pull w ithout Heijunka Box

Information Pull

Material

Pull

Option Process

Only some % goes

through option

process

Frequent Material w ithdraw al using Heijunka box.

Frequent

Withdrawal

Material

Pull

Tool to level production by Volume & Variety over a specif ic amount of time.

Heijunka

Box

Assy Shipping

Staging Area

Assy.

3

Heijunka

A

BC

Assy

33

Staging

3

Cust.

Note: Identify Pitch 5'

A

B

C

3

StageAssy

Production Control

Bumper load

masking

punch

80%

20%

Supplier Customer

Assy.

1 wk

Accumulation location for parts or material directly follow ing a process or operation w ith predetermined quantity requirements.

Variety Size

StampingSupplier Assembly Customer

N=2 diff parts N=4 diff parts

Stamping Stamping Stamping Stamping

Max Qty = 2 Max Qty = 10

Heijunka Box

1 hr

5 hr

Identif ies material or information stagnation. Size of symbol show s

amount of stagnation.

Body Weld

part1xqty

part2xqty

part3xqty

A

B

C

Heijunka Box

EDMM 4870

11

Identif ies outside Suppliers (Parts or Materials).

Supplier Parts or

Materials, or outside

Processing

Each block represents one process.

Manufacturing Designates:

Process 1 x 1 or 1 kanban X 1 kanban.

on Line Each block represents one process.

Designates:

Batch Production

Material or Information

Stagnation

no rule - random

Temporary Store

Store

Material or parts pushed to the next process or operation w ith no

Push reference to need.

Material

Flow

Material Pull w ithout Heijunka Box

Information Pull

Material

Pull

Option Process

Only some % goes

through option

process

Frequent Material w ithdraw al using Heijunka box.

Frequent

Withdrawal

Material

Pull

Tool to level production by Volume & Variety over a specif ic amount of time.

Heijunka

Box

Assy Shipping

Staging Area

Assy.

3

Heijunka

A

BC

Assy

33

Staging

3

Cust.

Note: Identify Pitch 5'

A

B

C

3

StageAssy

Production Control

Bumper load

masking

punch

80%

20%

Supplier Customer

Assy.

1 wk

Accumulation location for parts or material directly follow ing a process or operation w ith predetermined quantity requirements.

Variety Size

StampingSupplier Assembly Customer

N=2 diff parts N=4 diff parts

Stamping Stamping Stamping Stamping

Max Qty = 2 Max Qty = 10

Heijunka Box

1 hr

5 hr

Identif ies material or information stagnation. Size of symbol show s

amount of stagnation.

Body Weld

part1xqty

part2xqty

part3xqty

A

B

C

Heijunka Box

12

EDMM 4870

Exercise #01

We will follow one product through a simple process. Your company takes a piece of 22 gauge steel that has been

heat treated by your supplier and will deliver it to you in quantities of 5,000 piece bundles (bundles weigh over 500

pounds).

Once they arrive, they are off loaded from a semi trailer, which takes about 30 minutes, and placed in an area near

the receiving dock, until the paperwork, which is sent to the materials department has been cleared; this usually is

about 2 hours. Only then will the material be moved to a warehouse where they are stored until they are needed;

about 10 minutes. They generally sit in the WH for 5 days.

A Master Schedule is updated each morning and the sheets are pulled for each order. For this example, the

requirement is 200 pieces, but the bundle is 500, so all 500 will go to the process. The time from the warehouse to the

trimming department is 20 minutes, where each piece is manually fed into a series of trimming machines, that

ensures the piece is truly square; value add time is 5 seconds per side; 4 sides. After this performed which has a

cycle time of 60 seconds, the parts are restacked and bundled and sat near the process to be picked up by a fork

truck. The team member in the cell manually writes the number of finished parts that were good (198), the two pieces

that were scrapped for a miss-load into the trimmer and this paper is sat on the bundle. The supervisor uses a radio to

call a fork truck driver to retrieve the material back to the warehouse (10 minutes) The ‘Production” paper work will be

taken by the fork truck driver back to the materials team, so they can enter this into their computer.

By the end of the trimming process, how long (in time) is the “Value Stream” and what % of time

has been value added?13

EDMM 4870

Materials

Department

Trimming; 60

seconds

Fork Truck

Dispatch

30m 2h 10m 5d 20m 20s

To convert to

seconds; 30 x

60 = 1,800

To convert to

seconds; 2 x

3,600 = 7,200

To convert to

seconds; 5 x

86,400 = 432,000

1,800 + 7,200 + 600 + 432,000 + 1,200 +60 = 442,860s.

20 seconds of value (trimming)

442,860 seconds

0.0045%

Summary:

In over 5 days and 3

hours; one unit has

20 seconds of value

added to it.

99.55% no value

added.14

FAX-

Email

a. How is Order information Received?

Kanban, Fax, e-mail, electronically, etc….

b. What is Frequency of Order Transmission? – Kanban cycle, once a week

– When is the order information received

by e-Kanban, how long stagnating (Bus. Hrs)

c. Are the parts sold by Heijunka?Is there fluctuation in the information?

(customer, each trucks, each parts)

Prog.

Elect.W

EDMM 4870

Eight (8) Step Approach for Developing a MIFC /VSM;

Step 1; How is the

Customer Ordering?

15

a. How is product staging and shipping connected? Product staging area : the place to collect products for only one truck based on order information

(When order prepared vs. ship?) Shipping area : the place to load the products collected at staging

area to truck. (when do the product ship?)

c. How are the products

delivered to the final

destination?By Direct or Consolidation system?

(if Consolidation, what is the stagnation for this?)

Does the truck run at equal intervals?

(have to confirm the schedule)

b. Is the Product staging area and Shipping area separated or not?Same area: Are there individual designated truck lanes? (Are there one or more?)

Separated : Is there a work Instruction? schedule? ( What, Qty, When, and How many trucks,

Visible status? Can you see status: i.e., ahead or behind?)

EDMM 4870


Step 2; What is happening to the product right before it ships?

16

C. How often are the products withdrawn?

How much?Make the pace of the production (TT, TCT) ;

Scheduled quantity conveyance (1box/time)

Frequent conveyance ;

Scheduled time conveyance; 15minutes / time?

24times / shift ?

1 turck

B. How is the order information changed to collection information?

Heijunk

a

post

When do T/Ms start to withdraw?

How long to complete?.or put together the order

information for one

truck

list

a. Is there any instruction to withdraw

from the ‘following process’?

kanban listor Or ?W

EDMM 4870


Step 3; What is happening to the product before shipping?

17

Store (by parts number ) Sequence store (by order seq) No rule -

random

a. How are the finished products managed?

b. How much capacity do the racks

have?

Method for determining the number

of shelves / rows: rows – product

type; depth

a) quantity withdrawn

b) lead time from start to output.

Ultimate goal of Kanban to keep only one

(1) piece for each type of product; i.e.,

high frequency and short lead time.

EDMM 4870


Step 4; How are the finished good being managed?

18

a. What triggers production? (instruction)

Fill-Up System of production by Kanban?

Electrical signal , Instruction information by sequence?

By the desire of the Supervisor?

b. How does the instruction

work and travel?

Is Kanban One by One (1 X 1)?

When lots are made, are products

produced in same sequence?

When the information is collected,

is production started or delayed?

EDMM 4870


Step 5; What is the production

Instruction Method?

19

Staging

Area

WI

Types of Production Instruction

Type A (Fill-Up production)

Withdrawal

Kanban

Process

Product

collection

Area

Production instruction Kanban Submit order and quickly

receive product (Short Lead

time)

Fill-Up Production Instruction ① 1 by 1 production

② Lot production

a) Fixed-Quantity

b) Fixed-Period

Parts are made in the sequence of orders to fill up only the amounts sold (kanban x kanban).

(Requires Production Repeatability.)

EDMM 4870


Step 5; Production Methods; explained:

20

Process１ Process２

◎

◎ ◎

◎

◎

◎

◎ ◎ ◎ ◎

Type B Order- Sequential production Capability of making items 1 X 1 is required.

Tablet – tool that is sent to beginning of process when product removed and authorizes

release of next product – controls total quantity in process.

Longer Lead Time

required for Production

(Production

sequence plan) (Tablet)

Raw material

(Collection

sequence plan)

Staging

Area

Must be able to produce items after receipt of orders in the sequence of the orders, so as

not to disrupt the production sequence.

Types of Production InstructionEDMM 4870


Step 5; Production Methods; explained:

21

It is intrinsically the best to make all items after receipt of purchase orders. Since such a production system

cannot level the workloads, a fill-up production system is applied to maintain a leveled production.

◎

◎Process

W

I

Card

Quantity of

items sold

(Filling-up) (Production to order)

Part number

Avoid excessive inventory of items.

Regular productionService parts or specially ordered production

Production sequence plan

Withdrawal

Kanban Production instruction Kanban

Staging Area

Delivery sequence plan

Types of Production Instruction

Type C (Combination of types A and B) Fill-Up production + Sequential production (total quantity control)

EDMM 4870


22

a. What is the machine capacity?

Compare T.T with MCT, Understand

Operational Availability & defect ratio

How to draw MIFC

b. How much Standard In-Process stock is required?

Manual Machine / Automatic Machine - How many for machine type & T/M flow?

Auto machine: Understand the machine process AND the Conveyance Process requirements

c. How long is the

Processing Lead Time?

Stagnation Time; Takt Time = 1 Min.,

Making parts = 27 parts

Total Time = 27 Min)

EDMM 4870


Step 6; What is performance of the Production Process & Lead time(s)?

23

How to draw MIFC

a. Pull System or Push System of Production

b. What is the Authorization to start conveyance?

What Conveyance Rule is being Used?

a) Scheduled time (30min), b) Scheduled Quantity(1 box), c) Human Intervention?

c. What equipment is

used for conveyance?

Forklift truck, Tugger,

Tugger & Dollies, AGV,

Manual Carts?

EDMM 4870


Step 7; What is method of

conveyance? Connection? Pathway?

24

How to draw MIFC

a. How to place an order with the supplier?

b. How are the parts delivered from

the supplier to the plant?

Direct, Milk run or Cross dock ?

Kanban, Fax, e-mail, electronically, frequency, Division # etc….

Inventory level, unload time・・・

Frequency of delivery?

EDMM 4870


Step 8; What are the Logistics

with the Supply Base?

c. How long is Supplier Lead time?

25

Production L/T

(Process)

Store of completed parts

Line

Total Lead Time

Material Stag.

① Information Stag.

② Information Stag

Production Line

Processing L/T

Example: Total Lead Time =

Production Lead Time + Logistics Lead Time.

Logistics L/T

(between processes)

Production L/T

(Process)

Total Lead Time = Σ Production L/T + Σ Logistics L/T

How to draw MIFC EDMM 4870

26

Production Lead Time＝①＋②＋③＋④＋⑤＋⑥＋⑦＋⑧

⑤ Processing Lead Time

① Inventory of completed parts

② Info. waiting collection ③ Info. waiting for Lot④ Production Instruction

Waiting

⑦ Emergency (Safety Stock)

stock ⑥ Inventory for

fluctuation (Buffer)

⑧ Inventory for different shift

Operating Times

Production Lead Time is a common measure that can show the result of your Kaizen.

Production Lead time for Pull SystemDefinition: When a P/I Kanban is pulled and produced back to store to when the Kanban is pulled again

How to draw MIFC EDMM 4870

27

Methods for Production Lead Time Reduction

Method for

Lead time reduction

① Withdraw high frequency

② Collect high frequency

→don’t use collecting post

③ Produce in small lots

④ Reduce Change over time

⑤ Reduce non-Processing

parts (Buffer–SIPS)

⑥ Reduce withdrawal fluctuation

⑦ Improve the stability of

the line

⑧ Improve production capacity Production Lead Time

= ①＋②＋③＋④＋⑤＋⑥＋⑦＋⑧

①inventory of completed parts

②waiting collection ③waiting formed Lot④waiting production

instruction

⑤Processing Lead Time

⑦ Emergency (Buffer)

stock

⑥ Inventory for

fluctuation (Safety

Stock)

⑧ Inventory for different

shift Operating Times

EDMM 4870

28

Logistics Lead time (Internal)

Logistics Lead Time＝①＋②＋α

Following

Process

Previous

Process

I

②Stock for 1 cycle

delivery time

Ａ

W

引引引W

Ａ

W

Ａ

W

Ａ

W

Ａ

I

Ａ

I

①# of W Kanban

detached during

1 cycle delivery time

αSafety stock for

fluctuation and abnormality

Definition: Time from when a withdraw Kanban is pulled

and delivered back to store to when the Kanban is pulled again.

EDMM 4870

29

仕入先Line

引取引取W

Staging

Production

①Supplier lead

Time

Supplier

⑥Kanban

Scanning

time

⑤Kanban

collecting time

④Stock at

line side

③Internal

conveyance time

②Unload time

Assembly Plant

Logistics Lead time (External)

Logistics Lead Time

＝①＋②＋③＋④＋⑤＋⑥＋α Safety stock for

fluctuation and abnormal

α1 α6

α5

α4

α3

α2

Definition; Time when a withdraw Kanban is pulled

and delivered back to store to when the Kanban is pulled again.

EDMM 4870

30

Heijunka of production

instruction

⑤ even pitch collecting

Even pitch truck schdule

④ review safety inventory

③ reduce fluctuation of

delivery volume

resolve traffic jams

② arrangement of empty

box and dolly

① High frequency,

Reduce delivery delay

Reduce QPC

Method for Logistics L/T Reduction

引取引取W

Production

Logistics Lead Time

= ①＋②＋③＋④＋⑤＋⑥＋α

Supplier

Assembly Plant

① External Delivery time

②Unload time

③Internal

conveyance time

④Stock at

line side

⑤Kanban

collecting time

⑥Kanban

Scanning time

Method for L/T reduction

EDMM 4870

α1

α6 α5

α3

α2α4

31

Common Mapping Errors

EDMM 4870

32

EDMM 4870

Common Mapping Errors

33

Kaizen points to consider

① Consider how to make & provide production

instructions.

② Consider Continuous flow and Smooth flow.

③ Consider store location in the flow.

④ Consider Inventory levels.

EDMM 4870

34

EDMM 4870

Exercise

Important principles of Mapping the flow:• Nothing moves on it’s own. There is something that needs to initiate the material to move

• Movement of the material, is almost always a “Waste”.

• When performing a value analysis, there are several denominators that are able to be used;

o Departmental

o Business Area

o Entire Plant

However, each denominator must have the numerator calculating the “Value”. So, if in a Department, the

value added is 120 seconds, and time in the Department is 3 hours, than the value is 120 seconds divided

by 3 hours. Similarly, if the Business area (which includes the above mentioned department, as 4 minutes

and 15 seconds, you can not keep using the Departmental time of 3 hours, now you must use the Business

Group; which happens to be 2 days, 8 hours and 40 minutes.

Representation of a

Department. 120

seconds of value and 3

hours of total time.

35

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