Professional Documents
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Materi Value Stream Mapping
Materi Value Stream Mapping
Mapping ACADEMY
Lean Thinking
Waste in Manufacture
Value Stream Mapping
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Lean Thinking
The Relentless Elimination of Waste
What is Lean ?
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adalah metode sistematis guna
[Definisi] memperpendek waktu
antara order konsumen sampai dengan
Lean produk dikerjakan / dikirimkan melalui
Lean Manufacturing
Business as Usual
WASTE PRODUK
ORDER KONSUMEN
DIBUAT & DIKIRIM
Time
Lean Manufacturing
PPRODUK
ORDER KONSUMEN
DIBUAT & DIKIRIM
Time (Shorter)
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Lean Thinking
Lean thinking can be summarised into five principles :
What is Value…?
Benefit
Value =
Cost
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The Value Stream
Mine Reduction
Mill Smelter
Hot
Roller
Cold
Can Roller Remelter
Can Maker
Warehouse Recycle
Centre
Bottle Tesco Tesco
Bottler Home
Warehouse Warehouse Store
Value stream for Cola Cans (Lean Thinking: Womack & Jones 1996)
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Waste in Manufacture
” Understanding & identifying waste is the first step to reducing or eliminating waste”
VALUABLE WASTE
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Rough Guide to Waste
TOYOTA defines Waste as:
"anything other than the minimum amount of equipment, materials,
parts, and working time absolutely essential to production."
Therefore: Any activity that does not change the product or assembly is waste
Definition of Waste
Effort frequently does not result in changing the shape or character
of a product or assembly
• eg. moving, counting, expediting, setups, inspecting, etc
The more waste you can see, the more you can eliminate
• If you accept activities as waste, you may devise methods to eliminate them.
YOU choose whether to tolerate the waste!
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Value Stream Mapping
” Mapping area of waste to be eliminated ”
Why Map ?
• Visualise individual value streams
• Uses a selection of tools to review a value stream
• Cross functional involvement & decision making
• Understand what wastes exist & where
• Enables the development of improvement plans
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Mapping Process
vs Value Stream Mapping?
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Information Flow
Material Flow
Lead Time
Timeline VA , NVA
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Map Layout Geography
Time Line
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current-state
drawing
future-state
drawing
work plan
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Product Family
A group of products that passes through common processing steps
and over common equipment in your downstream processes.
1 Process
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current-state drawing
ACME Stamping Factory Layout
PRESS DEPT.
Weld II Weld I SHIPPING
200 T WELDING DEPT.
Press
Finished
Goods
Welding Storage
Inspection Welded Parts Storage
Area
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ACME Stamping Material Flow
1. Supplier
2.
3.
Stamping
Spot-welding Workstation #1
Door to Door
4. Spot-welding Workstation #2
5. Assembly Workstation #1 Where should we start?
6. Assembly Workstation #2
7. Shipping
8. Customer
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What data should be collected?
Customer & Shipping, Supplier Process / Production
• Company Name • Number of product variations (P/N’s)
• Quantity order per month • Machine(s) used
• Working days, shift • C/T (cycle time)
• Quantity delivery per day • C/O (changeover time)
• Frequency of delivery/trucking • Uptime (on-demand machine time)
• Order information, forecast • EPE (production sequence time)
• Number of operators (dedicated)
• Pack size
• Working time (minus breaks)
• Scrap rate
• Inventory Before and after
Tues. +
Thurs. IN OUT 1x
Daily
Door Door
STAMPING
STAMPING I S. WELD #1 I S. WELD #2 ASSEMBLY #1
I
ASSEMBLY #2 SHIPPING
I I I
Coils 200 T 4600 L 1100 L 1600 L 1200 L Staging
5 days 2400 R 1 600 R 1 850 R 1 640 R 1
C/T = 1 seconds C/T = 39 seconds C/T = 46 seconds C/T = 62 seconds C/T = 40 seconds
C/O = 1 hour C/O = 10 minutes C/O = 10 minutes C/O = 0 C/O = 0
Uptime = 85% Uptime = 100% Uptime = 80% Uptime = 100% Uptime = 100%
27,600 sec./shift 2 Shifts 2 Shifts 2 Shifts 2 Shifts
EPE = 2 weeks 27,600 sec/shift 27,600 sec/shift 27,600 sec/shift 27,600 sec/shift
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Add Information Flow
Acme Production Control: Icons:
• 30/60/90 day forecasts from customer PRODUCTION
• Daily firm order CONTROL
• Weekly MRP generation
MRP
• 6 week forecast to supplier
• Weekly supplier releases Daily
• Weekly build schedules Order
• Daily shipping schedule
Weekly
Schedule
Daily Ship
Tues. + Schedule
1x
Thurs.
Daily
STAMPING
STAMPING I S. WELD #1 I S. WELD #2 ASSEMBLY #1 ASSEMBLY #2 SHIPPING
I I I I
Coils 200 T 4600 L 1100 L 1600 L 1200 L Staging
5 days 2400 R 1 600 R 1 850 R 640 R 1
1
C/T = 1 seconds C/T = 39 seconds C/T = 46 seconds C/T = 62 seconds C/T = 40 seconds
C/O = 1 hour C/O = 10 minutes C/O = 10 minutes C/O = 0 C/O = 0
Uptime = 85% Uptime = 100% Uptime = 80% Uptime = 100% Uptime = 100%
27,600 sec./shift 2 Shifts 2 Shifts 2 Shifts 2 Shifts
EPE = 2 weeks 27,600 sec/shift 27,600 sec/shift 27,600 sec/shift 27,600 sec/shift
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Add The Time Line
• Process lead-time is the Cycle Times (Value Added Time) for all of the
operations in the process.
Amount on Hand
Inventory Days =
Daily Customer Need
1x
Daily Ship
Daily
Tues. + Schedule
Thurs.
ASSEMBLY #1 SHIPPING
STAMPING
STAMPING
I
S. WELD #1
I
S. WELD #2
I I
ASSEMBLY #2
I
I Staging
Coils 200 T
1 1 1 1200 L 1
5 days 4600 L 1100 L 1600 L 640 R
2400 R 600 R 850 R
C/T = 1 seconds C/T = 39 seconds C/T = 46 seconds C/T = 62 seconds C/T = 40 seconds
C/O = 1 hour C/O = 10 minutes C/O = 10 minutes C/O = 0 C/O = 0
Uptime = 85% Uptime = 100% Uptime = 80% Uptime = 100% Uptime = 100%
27,600 sec./shift 2 Shifts 2 Shifts 2 Shifts 2 Shifts Production 23.6
EPE = 2 weeks 27,600 sec/shift 27,600 sec/shift 27,600 sec/shift 27,600 sec/shift =
Leadtime days
5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days
1 second 39 sec. 46 sec. 62 sec. 40 sec. Value
Added = 188 sec.
Time
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Identify Opportunities
• The Current State Map shows what is happening “right now.”
• It identifies wasteful steps and bottlenecks.
• It helps visualize how operations can be combined to “flow”.
• It lets you see where “pull” systems are needed
• It shows how the improvements impact the value stream.
Daily Ship 1x
Tues. + Schedule
“flow” cell
Daily
Thurs.
pull pull
pull
STAMPING
STAMPING I I
S. WELD #2 ASSEMBLY #1
I
ASSEMBLY #2
I S. WELD #1
I SHIPPING
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Push vs Pull Control Systems
MRP/
Push System
Planning
System
Make to the plan/schedule
Work-To-Lists
Work-centres are independent
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Kanban : A Simple Real Example
Burger
Kitchen Regulator Tills Customer
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Future State Questions
1. Desired cycle time (Takt time)?
Demand
2. Built to a FG supermarket or direct ship ?
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What is Takt Time ?
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Allocation of Resources
Required Takt time = 2.4 min
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Direct Ship or Supermarket?
Use direct ship when continuous flow, mixed model production can be
done. Withdrawal
Card Customer
Requirement
ASSEMBLY SHIPPING
Supermarket
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Future State Question #3
• Where can you use continuous flow processing?
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Continuous Flow
Current Cycle Times: After Improvement:
62s.
60 56s. 56s. 56s.
45s.
ASSEMBLE
39s. 40s.
ASSEMBLE
40
ASSEMBLE 1
ASSEMB. 2
WELD
WELD 1
WELD 2
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WELD
1s.
0 1 1 1 1 1 1 1 1
= 1 + 39 + 45 + 62 + 40 = 186 – improvement
= 187 / 60 = 3.12 Ops = 168 / 60 = 2.8 Ops
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Where Can Supermarkets Be Placed?
Use production supermarkets when batching is necessary due to:
• Short cycle times in lead-off ops
• Multiple customer cells
• Long setup times
• Long or unreliable processes
• Distant outside supply
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Where is the Pacemaker?
• The pacemaker process is the only one in the value stream that you
schedule.
• It sets the pace for and pulls from the upstream processes.
Supermarket FLOW
Supermarket FLOW
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Future State Question #6
• How will you level the production mix at the pacemaker process?
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Production Mix
Normal batch scheduling would be:
1st shift 2nd Shift
LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLRRRRRRRRRRRRRRRR
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Achieving the Future State
1. Breaking Implementation into Steps:
• You can circle these loops on your future-state map, to help you see the flow segments
that make up your value stream.
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Achieving the Future State
3. Value Stream Improvement is Management’s Responsibility
BP #3
Steel Co. Assembly
Daily
Daily
500 ft. coils Order 18,400 pcs/mo
Order - 12,000 LH
coil Loop
- 6,400 RH
Tray = 20 pcs
2 shifts
coil Daily Order
coil
Daily 1x
Milk Run Daily
OXOX 20
batch 20
20
tote
BP #1
Loop
Coils
STAMPING WELD + ASSY.
L Pull SHIPPING
R
200 T Staging
BP #2
EPE = 1 shift
Takt = 60 sec.
Loop
C/O = < 10 min.
C/O = 0
(at the Uptime = 100%
press) 2 Shifts
Total work content
-
Production
1.5 days 1 day
< 168 sec.
2 days leadtime = 4.5 days
1 sec, 168 sec. Value
Added Time = 169 sec.
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Thank You
PRODUCTIVITY ACADEMY
prodemy.global@gmail.com
: 082112235378
: Productivity Academy ID
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