Data Collection

Process Name:

Step #: 1
Setup Time (min.): 12
Cycle Time (C/T) (min.): 3
Changeover time (C/O) (min.):
30
No. of people: 1
No. of shifts: 2
No. of workstations: 5
First Pass Yield (FPY) (%):
Capacity:
Downtime:
Scrap Rate:
Batch Size:
Distance between ops:
Drilldown
Material scrap %:

Rework required %:

Rework time:

Additional:

Additional:

Notes:
VSM Instruction Sheet
The six primary steps to completing a VSM include:

1 Identify and select the product family that needs mapping

2 Determine the goal(s) for improvement
3 Select the team (kaizen sub-team) for data collection and mapping
4 Think through the flow of the process and collect the data
5 Based on customer's needs, determine effects of scheduling
6 Draw out the Value Stream Map

Data Collection Instructions:

Start at the end of the process and work backwards. At each step, process, or workstation, follow the actual
routing of either the work or the information, depending on the value stream you are focused on. Record
1 every individual process step.

Determine inventory at each step. Look for levels of WIP then ask if extra materials for use at this step are
2 stored in other locations. Capture and record all inventory.

Observe setups and changeovers, then record times. Take close note of the movement of people and
3 inventory; look for waste at every opportunity.

Determine product runs. Ask operators how often particular products are run and how often the WIP is
used. Determine how quickly WIP is used up. Record average WIP levels.
4

Determine cycle times. Use a stop watch and time everything yourself. Do not rely on anyone to offer you
5 the actual times. Verify all timing as it actually runs.

Observe actual number of people used in the process. Compare the number to what is actually listed per
the manning requirements. Ask if other people are need to help move equipment or material during normal
operation. Determine if operators are following written procudures or are using their own version. Look for
6 excess waiting or walking and observe problems with ergonomics.

7 Record number of shifts and workstations used in the process.

From existing metrics (KPI's) record historical FPY, downtime, and capacity if available. If not, record these
8 over the course of a few days if possible.

Observe and record scrap rates, batch times, and distances between workstations.
9
In the overall processes, be sure to distinguish between cycle times, takt times, and transportation times.
10

Add notes:
Copy and paste from the tools section and use the MS Excel "Shapes", or use the pre-built MS Visio shapes to build your map
S Visio shapes to build your map.