vsm 1hr presentation
TRANSCRIPT
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United Technologies Lean TransformationUnited Technologies Lean Transformation
Lean / Value Stream
Mapping Overview
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gendagenda
! Lean "rinciples
! United Technologies# Vision
! $hat is Value Stream Mapping
! Seven Steps to Lean
! %uilding Lean Organi&ation
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(oots of Lean Thin)ing(oots of Lean Thin)ing
! *ord+ ,ighland "ar)+ 1-1'
! M+ Mied Model 0 %atch "rocess+ 1-'01-
! Ohno+ merican Supermar)ets+ 1-3#s
! To4ota "roduction S4stem+ 1-301-50now
! 6Lean7
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$omac) and 8ones$omac) and 8ones
6Lean Thin)ing7 3 principles+6Lean Thin)ing7 3 principles+
10 Specif4 value
20 Map the flow of value
'0 Ma)e value flow
0 "ull from the customer
30 See) perfection
8im $omac) and 9an 8ones:
Lean ;nterprise
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United Technologies#United Technologies#
>ontinuous
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VisionVision
Suppl4 >hain VisionFda4sG
Customer
Order Raw MaterialAssembly
& Test
Procurement
Cycle
Order
Cycle
>urrent Suppl4 >hain
Fwee)sG
Delivery
Cycle
Assembly
Cycle
ShippingManuacturing
!"#$A
!A%
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The TransformationThe Transformation
6onnecting
the 9ots7
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dding a tool to the >; ToolHodding a tool to the >; ToolHo
5SP asspor t
St andar d W or k
Mar k et F eedback Analy sisMist ak e P r oofng
Pr ocess Management
V alue St r eam Management
Root C ause C or r ect iv e Act ionP r ocess C er t ifcat io
n
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$hat is a Value StreamI$hat is a Value StreamIll activities Hoth value added and non0
value added reJuired to Hring product
from raw material to the customer alue Stream
Customer
"roducer
>USTOM;(
(aw
Material
*inished
"roduct
"roducer
%
"roducer
>$arehouse
ssemHl4 =
Tet
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$hat is Value Stream$hat is Value Stream
MappingIMappingI
Current StateMap
Current StateMap
Future StateMap
Future StateMap
mplementationPlan
mplementationPlan
Product Family!efnition
Product Family!efnition
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;ample of a >urrent State Map;ample of a >urrent State Map
>ustomer (aw MaterialSupplier "roduction>ontrol
-/C/'
da4 forecasts
9ail4
Order
C $ee)
*orecast$ee)l4 *a
Producer A
1' parts '3 parts
I
Shipping
3 parts
$ee)l4 Schedule 9ail4Schedule
' da4s '3 da4s 3 da4s
3 hours 1 hours 2 hours
Leadtime
= 270 days
Processing
time = 35 hrs.
Producer %
1
Assembly
1
2 da4s
>/T K 3 hr.>/O K 1 min.
Uptime K ?
>/T K 1 hr.>/O K 1 min.
Uptime K ?
>/T K 2 hr.>/O K 1 min.
Uptime K ?
I
I
I
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$hat defines a "rocess on a Value Stream MapI
$here inventor4 stops an accumulates
Mill Turn rind ss4
Mill Turn rind ss4
,ow man4 processes are thereI
,ow man4 processes are there nowI '
(
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Set)up Total *or+
,-. hrs
ShippingPart
Producer
Assy &
Test
%atch
;ample of a *uture State Map;ample of a *uture State Map
9ail4
Schedule
Lead-time
= 47 days
Processing
time = 25 hrs.
>ustomer (aw MaterialSupplier "roduction>ontrol
-/C/'
da4 forecasts
9ail4
Order
C $ee)
*orecast$ee)l4 *a
23 da4s 2 da4s
1 hrs 13 hrs
2 da4s
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Value Stream Mapping dvantagesValue Stream Mapping dvantages
! Measures value from a customer#s perspective
! *ocus is on lead time
! Shows a s4stem view! Lin)s the material and information flows
! ;naHles the organi&ation to identif4 waste
! "rovides a roadmap for continuousimprovement = change
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The *uture State is 9efined UsingThe *uture State is 9efined Using
Seven %asic "rinciples of LeanSeven %asic "rinciples of Lean10 Ta)t time
20 *inished goods strateg4
'0 >ontinuous flow
0 "ull S4stem
30 Schedule onl4 one point
C0 "itch
50
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11stst+ Ta)t Time+ Ta)t Time
S4nchroni&e the paceof production to the
pace of sales
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22ndnd+ *inished oods Strateg4+ *inished oods Strateg4
%uild to Stoc)
%uild to Order
or
,4Hrid
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'. minutes
'. minutes
%atch & /ueue Processing
$ead)time 0 1 minutes or total order
'. minutes
ProcessA
Process%
ProcessC
-.22
''rdrd+ >ontinuous *low+ >ontinuous *low
Process%
ProcessA
ProcessC
One0"iece *low- min3
'4 min3
"rocess 1 "rocess 2*
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>ustomer goes to supermar)et and gets what the4 need when the4 need it
Supplier produces to replenish what was withdrawn
supermar)et
suppl4ing
process
customer
process
production
)anHan
withdraw
)anHan
withdrawn
product
new
product
"ull when flow is not possiHle
thth+ "ull S4stem+ "ull S4stem
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33thth+ Schedule Onl4 One "oint+ Schedule Onl4 One "oint
low
>ustomer
Supermar)et
!low
>ustomer
*
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CCthth+
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55thth+ "itch+ "itch
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*uture State 0 $hat to epect*uture State 0 $hat to epect
9rumHeat Set the pace
"itch Level the volume
*low / "ull / "acema)er $hat do < wor) on net
Operational Changes
;";< Level the mi
Lead0time decreasing
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%uilding the Lean Organi&ation%uilding the Lean Organi&ation
;ver4 one of us must reali&e that+
the compan4 is in Husiness Hecause of our customers
Our customers have choices
those choices la4 with our competition
waste adds cost: time: and service interruption thus
giving the advantage to the competition
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Supporting the Lean Organi&ationSupporting the Lean Organi&ation
t ever4 levelN
Understand what is important to the customer
See the flow of value
(ecogni&e waste
Solve proHlems that interrupt the flow of value
>ontinuousl4 improve the flow of value