Lean Engineering Concepts

ENMG 642

Lecture 5- Process Mapping

TOC Presentations
What is a process?
Identify the Customer
Five Lean Thinking Fundamentals
Specify Value
Value
The inherent worth of a product as judged by the customer
and reflected in its selling price and market demand.
Lean Lexicon 2008
Value Added and Non Value Added
Identify the Value Stream
Value Stream
▪ All of the actions, both value-creating and nonvalue-
creating, required to bring a product from concept to
launch and from order to delivery.
▪ These include actions to process information from the
customer and actions to transform the product on its way
to the customer.

Lean Lexicon 2008

What is a Value Stream?
What Moves In a Value Stream?
Seven Types of Waste
Make Value Flow Continuously
Making Value Flow
Time
Time

(https://www.mudamasters.com/en/lean-toolbox-lean-production-lean-transformations/takt-cycle-process-and-lead-time)
Time

https://www.slideteam.net/cycle-time-process-time-powerpoint-slide-templates-
download.html
Time

https://www.slideteam.net/lead-time-and-cycle-time-powerpoint-slide-deck.html
Kitting
Mistake Proofing
Let customers pull value
What is a Pull System?
Moving from Flow to Pull
Pull System: DELL COMPUTER
Kanban
Kanban
▪ Order card (Kanban) which indicates standard quantity of
production
▪ Derived from two-bin inventory system
▪ Advantages
✓ Authorize production and movement of goods
✓ Maintain discipline of pull production
Origin of Kanban
Kanban
When Do You Order?
Types of Kanban
▪ Production kanban
✓ Authorizes production of goods
▪ Withdrawal kanban
✓ Authorizes movement of goods
▪ Kanban square
✓ A marked area designated to hold items
▪ Signal kanban
✓ A triangular Kanban used to signal production at the
previous workstation
▪ Material kanban
✓ Used to order material in advance of a process
▪ Supplier kanban
✓ Rotates between the factory and suppliers
Kanban

https://www.youtube.com/watch?v=rkpadFfyCqo
Andon Systems Help Prevent Mistakes
Pursue Perfection
Pursuing Perfection
Five Lean Fundamentals Work Together
Value Stream Mapping
Value Stream Mapping
▪ It is a tool that helps visualize the stream of activities in
order to eliminate all types of waste and ultimately leading
to an improved process
▪ Taking a value stream perspective means working on the
big picture, not just individual processes, and improving
the whole rather than optimizing the parts
▪ It is a collaborative tool that can be understood by all
involved
▪ it is used to describe, design and eventually communicate
the new desired situation

(Rother and Shook, 1999)

Value Stream Mapping
▪ A simple diagram of every step involved in the material and
information flows needed to bring a product from order to
delivery.
▪ A current-state map follows a product’s path from order to
delivery to determine the current conditions.
▪ A future state map deploys the opportunities for
improvement identified in the current-state map to achieve
a higher level of performance at some future point.
Lean Lexicon 2008
Eliminate…
▪ Muda: non-value-added
▪ Muri: overburdening resources
▪ Mura: unevenness
Value Stream Mapping

http://www.youtube.com/watch?v=HKxL_S47yJg
Steps for Creating a VSM

https://www.youtube.com/watch?v=lTobwIsGm_g
Steps for Creating a VSM
What are the states in which we can find materials or
information in a process?

Being
inspected
Undergoing
transformation
Being moved

Being
reworked

Waiting
 Example
(Source: Rother and Shook, 1999)
Example
Value Stream Mapping Icons
Value Stream Mapping Icons
Acme Stamping Data Set
Key Points
▪ Current state maps are useless without future state maps
▪ Future state maps cannot be realized without sufficient
understanding of the current state
Create a VSM - Future State
1. What is takt time?
2. Will you build to a finished goods supermarket from which
the customer pulls, or directly to shipping?
3. Where can you use continuous flow processing?
4. Where will you need to use supermarket systems?
5. At what single point in the production chain will you
schedule production?
6. How will you level the production mix?
7. What increment of work will you consistently release?
8. What process improvements will be necessary?
(Rother and Shook, 1999)
Future State Map
Terminology
▪ Available working time ▪ Load leveling box (heijunka)
▪ Changeover time ▪ Pacemaker
▪ Continuous flow (vs pull) ▪ MRP
▪ Cycle time ▪ Product family
▪ EPE
▪ Takt time
▪ FIFO
▪ Implementation plan ▪ Uptime
▪ Inventory ▪ Value
✓ Raw materials ▪ Value stream
✓ Work in process ▪ Value stream map
✓ Finished goods ✓ Current state
▪ Kanban ✓ Future state
✓ Production ▪ Value added time
✓ Withdrawal ▪ Rework
▪ Lead time
Why is VSM a Useful Tool?
Tips for Creating a VSM
Team Project
Guidelines