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Value stream mapping is a lean tool that can be used to map processes
in detail, based on the both the flow of material as well as information.
Data boxes make it possible to write important aspects of each process
step, such as changeover times, cycle times and machine availability,
which makes value stream mapping a great tool to use in (re)designing a
value stream (Panneman, 2017). In traditional lean initiatives, a current
state value stream map is drawn first (described here), after which a
future state map can be designed which is described in the article: 8
Steps of Future State VSM.
To get to know different symbols of value stream mapping and when to
use which one, I will describe an example process, the production of
lighters, and map it step by step. This example is copied from the
book: Lean Transformations (Panneman, 2017). The different steps will
be shown in the slideshow below. We start with the product flow first,
followed by the information flow. To create your own value stream map
using the symbols discussed in this article, get your free download of our
template.
Process time is the time one product spends in a process step. This can
be measured with the red-dot principle. Put a red dot on a product
before it goes into a machine and measure how long it takes for it to
come out on the other end.
Cycle time is the time between two products coming out of the process
step. For regular and one piece flow boxes, the cycle time and process
time are the same. For batch- and parallel processes, the cycle time is
shorter than the process time because multiple products are worked on at
the same time, and for shared resources, the cycle time is longer than
the process time, because the machine is not producing products for this
value stream all the time.
Availability to show how often the machine is available for this particular
value stream
Change over (C/O) can be used to log how long it takes to change over
from one product in the product family to another.
Batch can show how many products are worked on at the same time,
and EPEI (every product every interval) can show the maximum lead time
for on product within the family.
The third step is to draw the CONNECTION METHODS between the
process boxes. There are three possibilities, all show in illustration 3.
Push (unstructured) inventory. Between molding and painting, a
traditional push method is used. The shared resource is very expensive to
use, so when it is available it just produces as many products for our
product family as possible. This type of inventory is drawn with a triangle
and a dotted arrow and means the inventory has no maximum number of
products and no sequence in which the products are used at latter stage.