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VSM OLD

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15 views

VSM OLD

Uploaded by

amit
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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VSM

(Value Stream Mapping)


What Is VALUE ?

How Will You Measure it ?

*Cost is a Resultant of VA Process.


*Value is Flowing on the process/Shop floor.
*Value is an attribute, we have to convert it in
to measurement
Value Addition

 Output= Intput
No Value Addition

 Output= Input
Value Addition
Concepts

 Lean Philosophy
 Kan-Ban
 Muda
 Supermarket
 First Time Quality
 OEE
The Lean Philosophy

Lean Production occurs when


each Operation in the Value
Stream Produces exactly what
the next operation needs,
exactly when they need it,
with minimum waste!
The Hidden Factory

- Up to ¼ of every plant equipment,


personnel, Materials & Floor Space is
wasted performing the NVA work of
finding, fixing & replacing mistakes &
defects.
Manufacturing Waste - MUDA

Inventory – Sleeping Money


Defects – Cost of Find, Fix or replace
Transportation On material
Unnecessary Motions
Unnecessary Operations
Waste Of Waiting
Waste Of Over production
Waste Of Human Potential
Value Stream Mapping is a Lean
technique used to analyze the flow
of materials
and information currently required
to bring a product or service to a
consumer.

At Toyota, where the technique


originated, it is known as "Material
and Information Flow Mapping"
Value Stream Mapping

VSM is a tool that helps one to see &


understand the overall flow of
material & information as a product
or services makes its way through
an end-to-end process.
How ?

VSM Process Site Enablers Target Outcomes

Appoint a site Implement Lean


Value Stream principles, eliminate
Leader.
sources of waste
Choose Process Site Leader ship & accelerate the
Families (Commitment) creation of a
Develop a competitive supply
Current State chain.
VSM
See the Waste/ Site Vs Leader
Opportunities (Execution)
Develop a Future
State VSM Site Vs Team  Customer
(Execution) Driven
Develop & Execute
a working Plan  Lean
VSM Team
Maintain & (Support)
Expand the
VSM Process
1. Appoint a Leader

2. Choose the Process Family


Process Level

Single Plant
(G2G)

Multiple Plants

Across Companies
2. Choose the Process Family
(Identify the Value Streams)
OPERATIONS
Shear Punch Form1 Form2 Weld1 Weld2 Debur

P1 X X X X X
P2 X X X X X
P3 X X X X
P4 X X
P5 X X X X
P6 X X
3. Develop A Current State VSM

 Value Stream Mapping begins with


door to door product flow analysis
 The initial walk-through is followed
by additional , more thorough,
information gathering walk-throughs

Process Flow

Welding Riveting Inspection Packing

Walk, Map & collect Information


Operations Data Collection Form
C/T (Cycle Time)
C/O (Change-over)
Part No.
UT (Up-Time)
MT (M/c Time)
AT (Available Time)
WT (Waiting Time)
FS (Floor Space)
FTQ (First Time Quality)
Shifts
Others
Inventory Data

*Count The no. of pieces of each stage

- Including RM Inventory store


- Including WIP Inventory
- Including FG stores

•Divide the no. of pieces of inventory by the


average daily dispatch to determine the no. of
days of inventory at each location.
Current State Mapping Icons
Process Scorecard Measures
 Rolled Throughput Yield : FTQ of all operations
multiplied
 Process Lead-time Days : VA Time + NVA Time
 Process Efficiency % : (VAT/Process Lead time) x 100
 Inventory Days : No. of pieces divided by Daily sales
(RM,WIP & FG)
 Floor Space : Total Sq. Footage of Production +
Inventory Store
 Labor Productivity Ratio = Avg. Daily Sales/ No. of
Operators
 Process OEE = Avg. of OEE measures of all
operations in the process
Future State Maps

 Future State Maps Describe the


Value Stream as it could be – Ideal
State!

 The Future state Map is the


BLUEPRINT you will use to plan
improvement projects.
Future State Design question

 What Is TAKT Time


 Where can you deploy CONTINUOUS FLOW
 Where will you use SUPERMARKET PULL
 Will you build to a shipping SCHEDULE OR TO
A SUPERMARKET / KANBAN
 At what single point in the VS will you
SCHEDULE Production
 How will you LEVEL the production Volume
 How will you level the Production Mix
 What Kaizen Projects will be needed
Takt Time

Synchronizes pace of production


to match pace of sales

Takt time= Operating Time per Shift


Customer Requirement
Flexibility & Cell Design
Product A Product B

Product A & B Product A & B


Operator Balance Chart-
To achieve continuous flow

35
Takt Time= 30 sec 35
30 30
25 25
20 20
15 15
10 10
5 5
0 0
op1 op2 op3 op4 op1 op2

No. of Operators needed is determined


by dividing the Total Work Time by the
Cell Takt Time
Supermarket Pull With Kanban

 Customer goes to supermarket


& withdraws what they need
when they need it

 Supplying process produces to


replenish only what has been
withdrawn
Every thing Is GOOD
In the WORLD
AND

We can make it BETTER.


Thank You

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