The Value of Value Stream Mapping

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The Value of Value Stream Mapping
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Bill Greider September 8, 2009

• Whenever there is a product for a customer,
  there is a value stream. The challenge lies in
  seeing it

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What is a Value Stream

• The specific ACTIVITIES required to design,
  order, and provide a specific product from
  concept to launch, order to delivery, and raw
  materials into the hands of the customer

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Why Value Stream Mapping?

• Helps us to see the 8 wastes in our value stream
• Helps us identify
• Value-added activities-what your customer will
  pay for
• Non value-added activities- things you do your
  customer wont pay for
• In our communication processes

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P4-Process-LEAN tool box

• Value Stream mapping

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Why Value Stream Mapping?

• Making the 8 wastes visible
• Defects (correction of mistakes, rework)
• Overproduction (faster than necessary pace)
• Waiting (customer isnt paying you for cure time)
• Non-value added processing-how long do I mix, how
  long do I roll?
• Transport-loading, unloading, driving pails
  sand around
• Inventory-tools, materials going for the ride
• Motion-walking but not working
• Employees underutilized/under-trained-I better do
  the topcoat, on-the-job training

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A few assumptions

• If you are faster than your competitors, you can
  win
• Time is the only currency
• By eliminating the non-value added activities you
  improve productivity
• This exposes further waste problems become
  visible

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Seeing the Current State

• Need to be done at GEMBA
• Bring your stopwatch
• Map the entire stream yourself in pencil on your
  template provided

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Some LEAN measurements (all time)

• Process time the actual time it takes for the
  process to be completed, as timed by observation
• Value-Added time how long it takes to give the
  customer what they will pay for
• Lead time How long it takes to deliver 1 square
  foot of floor (one unit)
• Takt time available production time divided by
  the rate of customer demand

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Value Stream mappingIf you dont consider time,
it is coming out of your PROFIT
Find quote Find/order Materials Deliver
materials Schedule job Schedule crew
Receive Unload load
Flex Ships to you
SHIP IT! 1500 sf DAQ
X sf/min
X sf/min
Takt1.2 sf/min
Flex Ships to job
X sf/min
Sort
Wait-Cure
X sf/min
X sf/min
Pack up
Prep/prime/cove
1st bcst or slurry
2nd bcast Or grout
Grout/ /topcoat
Topcoat
Clean up
X sf/min
X sf/min
X sf/min
X sf/min
X sf/min
PTx sf/min
VATx sf/min
Note 4 or 5 mix station set-ups
X sf/min
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How did we do on that job?

• Not did we make money-dont focus on
• Did we meet takt time
• What was our SF per Minute?
• What are our Kaizan opportunities?
  (countermeasures)
• What problems can we see?
• Can we go to the film?

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Game Plan

• Develop a vsm for a weekend installation
• Provide a template for capturing square feet per
  minute from the time
• Truck loaded in shop
• Customer uses his floor
• Collect and share actual job maps

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