Overview
Value Stream Mapping is a lean manufacturing technique used to analyze the flow of materials and information currently required to bring a product or service to consumer. It identifies and demonstrates waste in the process.
When is it used ?
To identify value added, non value added activities & the time spent in step of a process that delivers customer value. To identify inputs flow through the system in creating final customer value. To identify, demonstrates waste in the process. To visualize and understand flow or lack of it . It makes Area of Waste visible.
3. Establish Current Level Performance 4. Map Current State 5. Identify VA /NVA / bottlenecks & establish baseline
Measure the current level performance for the identified value streams Compute effort spent vs. available capacity. As a first step will a 5 Why or is there a need to do a VSM
To understand reality do a VSM for the identified streams Focus on end to end value stream Capture value flow as well as information flow.
Carefully study the VSM to segregate real waste from essential activities Identify value/ information flow to identify wait times and bottlenecks Calculate process efficiency , throughout productivity Establish baselines
Measure new Process Efficiency Take the future state map as baseline for further improvement Measure actual performance of the value stream
Value Add
Activities th like was at look te but ar e necessa ry so the subsequ en add valu t can e minimum with waste
Reduce
An activ ity transform that s input, th the ereb bringing y closer to it the form req uired by the custome r
Types of Wastes
Overproduction/ Duplication Transport/Transfer Waiting
Movement
astes ven W Se
Inventory
Overprocessing
Defects
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What does the customer really need? How often will we check our performance to customer needs? Which steps create value and which are waste? How can we flow work with fewer interruptions? How do we control work between interruptions? How will work be prioritized? Is there an opportunity to balance the work load and/or different activities?
Benefits of VSM
Quick and easy to learn It helps portray the process from the start of the production process to the end It help finds bottlenecks It helps find waste within the process Its an inexpensive tool all you need is a paper and pen! It can be easily critiqued by your workforce (using post it notes) to highlight problems that exist within the process Its not just for manufacturing! Value stream mapping has been used in offices, service industries healthcare etc.
Limitations OF VSM
This situation sets up unrealistic expectations and diverts attention from important aspects of complex problems.
There may also be quality issues that the company could address through Six Sigma or TQM techniques. 5S can clean up the plant, improve safety and further raise productivity. Value Stream Mapping addresses none of these directly.
Many VSM symbols may lead the user to employ these techniques even when they are inappropriate
Fuzzy Definitions
The map does not begin to capture "all specific actions "Value Stream" conjures a vision of water running through a series of value-adding activities. But many icons do not depict value adding activities, do not touch the product and do not flow like a stream.
Training
A VSM group requires training on symbols and mapping techniques and on the Lean manufacturing elements that the symbols represent this contrasts with Process Mapping which only requires a trained facilitator.