LEAN

MANUFACTURING
Module-2
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POM04
Value Stream Mapping

 A very powerful tool for implementing the lean
transformation process is Value Stream Mapping (VSM).

 Value stream mapping is a pencil and paper tool that
helps you to see and understand the flow of material and
information as a product makes its way through the value
stream.

 A value stream is all the actions (both value added and
non-value added) currently required to bring a product
through the main flows essential to every product.


2
Value Stream Mapping
Current State Map
Follow a product’s production path from customer to supplier,
and carefully draw a visual representation of every process in
the material and information flow.

Future State Map
 Ask a set of key questions and draw the map of how value
should flow in the future (desired flow).


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Value Stream Mapping


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Value Stream Mapping


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Steps
Select one value stream - a product family
Walk the physical flow of material – no data collection
Walk the flow again, collecting data
Draw the Current State Map
Identify opportunities to eliminate waste and create flow
Draw the Future State Map
Generate a Value Stream Plan
Start making the improvements
Conduct Value Stream Reviews
Repeat the cycle
Selecting a Product Family


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A Product Family
A family is group of products that pass through similar processing
steps and over common equipment in the downstream process and
have similar work contents.
Value Stream Mapping Icons
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Value Stream Mapping Icons
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Value Stream Mapping Icons
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Terms one should know before
mapping
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Customer Need
Demand : Number of units per day the customer wants.

Available Working Time: Scheduled working time minus breaks
,meeting and clean up time
Inventory
WIP : Number of units waiting to be worked on or waiting to be
moved.

Finished: Number of units in stores or waiting to be shipped .
Terms one should know before
mapping
11
Each Process Step
Cycle Time : The time between one part coming off the process
and the next part coming off.

Number of people: Required to operate the process

 Uptime: The percentage of time the equipment is available to run
,when it is needed to run

Batch Size: Typical lot size or minimum.

Change Over Time: The time from the last good piece of one
batch to the first good piece of the next batch.

EPE…..Every part every ____ .How often do you changeover to
produce this part.

Terms one should know before
mapping
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Each Process Step
Takt Time –TT : Available time per day/demand per day.

Inventory(Measured in days) = Number of units /demand
per day



 Overall Flow
 Process Lead Time : The time for a unit to make all the way through the
process (Sum of Inventory days + Sum of Cycle times).
 Processing Time: The time actually spent performing work on the unit
(Sum of Cycle times)
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ACME STAMPING CASE
STUDY
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What’s wrong with Acme’s Value
Stream?
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Traditional mass production thinking about economies of
scale
Batches pushed through = Waste
 Look at VA time compared to time in plant