LEAN FLOW MAPPING - Lean Flow Consulting

1 Module LFM101 -Release USCopyright 2003-2008 Philippe Magnier All rights reservedLean Flow ConsultingCreating World-Class lean EnterpriseLEAN FLOW MAPPING -MODULE LFM101 -VALUE STREAM MAPPINGM odule LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedLEAN FLOW MAPPINGVALUE STREAM MAPPING Value Stream. Process. Value Stream Map Icons : Process, Data Box, Flow, Inventory & Work-In-Process. Value Stream Manager. Value Stream MAPPING Current State : ABC Stamping Company, Case Study & Practical LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGDEFINITION Whenever there is a Product, or Service, for a Customer, there is a Value The Challenge lies in seeing The Challenge lies in seeing LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGOBJECTIVES Introduce Value Stream MAPPING (VSM) in a Hands-On Manner.

2 Develop your ability to "See the Flow" and Design Future State Value Stream by Eliminating LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGVALUE STREAM DEFINITIONS tampingSpot-WeldingShippingVALUE STREAMRawMaterialFinishedGoodProductionA ssembly All Activities, Both Value-Added and Non Value-Added,required to bring a Product, or Service, from Raw Material into the hands of the LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGPROCESS DEFINITIONPROCESSW eldingShippingAssemblyNVANVANVANVANVANVA VAVAVAVA Sequence of Value-Added and Non Value-AddedTasks.

3 Which transform Inputs brought by Suppliersinto Outputs required by a LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGOVERVIEW Follow "Step by Step" a Product from Beginning to Endof every Process in the, from Raw Material into the hands of the Customer. Draw, using Icons, a Future State of Material and Information flows . Create an Optimized Value Stream (Future State)focused on Value-Added BoxC/T = 10 = 60 = 95%XYZC orporationOutsideSourceMovement ofMaterial by PushingManualInformation FlowElectronicInformation FlowMonthlyScheduleInformationINOrdersMo dule LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGEXAMPLE200 TSTAMPING1I4600 L2400 RWELDING #11C/T = 39 sC/O = 10 minI1100 L600 RWELDING #21C/T = 46 sC/O = 10 minI1600 L850 RASSEMBLY #11I1200 L640 RASSEMBLY #21I2700 L1440 RStagingSHIPPINGU ltra SteelCarbecICoils5 days18400 parts

4 / month-12000 L-6400 RMRPPRODUCTIONCONTROLC/T = 1 sC/O = 1 hC/T = 62 sC/O = 0C/T = 40 sC/O = 02 shiftsTray = 20 partsFORMING1C/T = 39 sC/O = 10 minI460 L240 RTuesdayThursdayDaily ShipScheduleWeekly ScheduleWeeklyFax6-weekForecast90/60/30 daysForecastsDailyOrder1 xDaily500 ft CoilsModule LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGICON DEFINITIONS tampingSpot-WeldingShippingVALUE STREAMRawMaterialFinishedGoodProductionA ssembly Process (Dedicated or Shared): A series of Steps or Individual Tasks that must occur in a specific sequence to produce a Product, On Piece at a Time, through aContinuous Flow.

5 Work is completed Continuously between each Task Inside the LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGICON DEFINITIONS tampingC/T =Takt=Uptime =C/O =Spot-WeldingShippingAssembly Data Box : Takt-Time : Takt, (Operational) Cycle Time : C/T(At), Changeover Time : C/O(S/U), Uptime : Uptime, Effective Work Time per Shift, ..VALUE STREAMRawMaterialFinishedGoodProductionM odule LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGICON DEFINITIONS tampingSpot-WeldingShippingAssembly Flow : "Push" :Based on MRP II System, Creates Excess Inventory.

6 "Pull" : Based on Customer Demand. Nothing is produced until it is Needed =Takt=Uptime =C/O =VALUE STREAMRawMaterialFinishedGoodProductionM odule LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGICON DEFINITIONS tampingSpot-WeldingShippingAssembly Inventory (Work-In-Process) : Indicates the Inventory Count & Time, Observed Items (Parts, Pieces, Information) between Processing Steps (or Processes), Translated into Wait Time to clear Observed Quantity, according to the Customer STREAMRawMaterialFinishedGoodProductionC /T =Takt=Uptime =C/O =300 parts2 days300 parts2 days300 parts2 daysModule LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGFUNDAMENTAL TOOL TO.

7 Product FamilyProduct FamilyCurrent State DrawingCurrent State DrawingImplementationImplementationFutur e State DrawingFuture State for the Future How the Shop Floor Currently OperatesUnderstanding How the Shop Floor Currently OperatesDesigning a lean FlowDesigning a lean FlowDynamic DocumentModule LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGVALUE STREAM MANAGER Each Value Stream needs a Value Stream .. For Product Ownership, beyond functional Barriers. Responsibilities : Lead and Train Employees with the Objectives to : Draw the Value Stream Current State Map, Optimize Materials and Information flows , Draw and Implement the Value Stream Future State Map, Define Action Plans necessary to obtain Results.

8 Improve Continuously the Product Family Value Stream. Communicate Progress to the Top Management on LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGVALUE STREAM MANAGER Understanding How the Shop Floor CurrentlyOperates : Material and Information flows , from Raw Materials to Finished Goods : Draw using Icons, Follow all flows Yourself, Gather Real Data, on the Shop Floor : No Standard Times. Draw by Hand, with Pencil. Foundation for the Future FamilyProductProduct FamilyCurrent State DrawingCurrent State DrawingImplementationImplementationFutur e State DrawingFuture State DrawingModule LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGABC STRAMPING COMPANY (1/5) ABC Stamping Company (ABC) produces several components for vehicle assembly plants.

9 This case concerns one product family : A steel instrument-panel bracket subassembly in two types : one each for left-hand and right-hand drive versions of the same vehicle model. Theses components are sent to the Carbecassembly plant, the Customer. Customer Requirements: 18400 parts per month : 12000 of Type "L" (Left-Hand drive) and 6400 of Type "R" (Right-Hand drive). Palletized returnable tray packaging with 20 brackets in a tray and up to 10 trays on a pallet. The Customer orders in multiples of trays. One daily shipment to the assembly plant by truck. Work Time: 20 days in a month in 2 shifts operation in all production departments.

10 8 hours every shift, with overtime if necessary. Two 10-minute breaks during each shift. Manual processes stop during breaks. Unpaid LFM101 -Release USLean Flow ConsultingCreating World-Class lean EnterpriseCopyright 2003-2008 Philippe Magnier All rights reservedVALUE STREAM MAPPINGABC STRAMPING COMPANY (2/5) Production Processes: ABC's process for this product family involves Stamping a metal part followed by Welding and subsequent Assembly. The components are then Staged and Shipped to the Carbecvehicle assembly plant on a daily basis. Switching between Type "L" (Left-Hand drive) and Type "R" (Right-Hand drive) brackets requires 1 hour changeover in stamping and 10-minute fixture change in the welding processes.