Lean Value Stream Mapping Process - ADDVALUE - Nilesh Arora

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Value Stream Mapping
by
Best Performing Consulting Organization
Adding Value In Totality !!
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Learning Framework

1. Introduction
2. The Current State Map
3. Lean Value Stream
4. The Future State Map
5. Achieving the Future State
6. Conclusion

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Value Stream Mapping
Purpose

1. Introduce Value Stream Mapping in a hands on
   manner.
2. Develop your ability to see the flow and design
   future state value streams.

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VALUE-STREAM IMPROVEMENT and PROCESS IMPROVEMENT
VALUE STREAM
PROCESS
PROCESS
PROCESS
Assembly
Stamping
Welding
Cell
Raw
Finished
Material
Product
The Three Value Streams Raw Material to
Finished Product Concept to Launch Order
to Cash
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Value Stream Mapping

• Follow a products production path from
  beginning to end, and draw a visual
  representation of every process in the material
  information flow.
• Then, draw (using icons) a future state map of
  how value should flow.

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Using the Value Stream Mapping Tool
Product Family
Understanding how the shop floor currently
operates. The foundation for the future state.
current state drawing
future state drawing
Designing a lean flow.
plan and implementation
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Focus on One Product Family
Determine Product Families via Similar
downstream assembly steps and equipment
Process Steps Equipment Process Steps Equipment Process Steps Equipment Process Steps Equipment Process Steps Equipment Process Steps Equipment Process Steps Equipment
Spot Weld Robot Weld Flash Remove Paint Manual Assm. Fixtures Assm. Electronic Test
LH Steering Bracket
RH Steering Bracket
Instrument Panel Brace
Seat Rail
Bumper Brackets

PRODUCTS
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Levels of a Value Stream
Process level
Single plant (door to door)
Mapping level to start
Multiple plants
Across companies
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Time
Push
Current-State Map showing the Customer
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Team Tips

• Current State Mapping
• Mapping the current state
• Review the basic processing steps and calculate
  the takt time in your teams breakout room.
• Everyone draw while on the shop floor.
• Be sure to draw both the material
  information flows.
• Always introduce yourself to operators and tell
  them what you are doing Drawing the total
  factory flow as part of a training session.
  Show them your drawings.
• Select a scribe and combine your drawings into
  one current state map (in team area).
• Calculate total lead time versus processing time.
• Make an overhead transparency of the map and
  select presenters.

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Team Tips

• Current State Mapping
• Presenting your
• All team members go up front with presenter.
  State the product family and takt.
• Present from your overhead transparency. (Less
  than 5 minutes.)
• Start with the customer and information flow into
  the facility.
• State the lead time vs. processing time.
• What are the problems you see? Where did you find
  push and overproduction ?
• Share any future state thoughts you have so far.

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Value Stream Loops
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Load-leveling box
Kanban are responded to from left to right at
pitch increment
One row per product type
Kanban
One column per pitch here pitch 10 min
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An Example of Paced Withdrawal
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ADDVALUE Services
VALUE ADDED COACHING-VAC
BUSINESS COACHING
LIFE COACHING
Operation Excellence
Counselling
Team Excellence
Therapy
Adding Value In Totality !!
Business Excellence
Astrology
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AddValue at a glance
Best Performing Consulting Organization
Business Coaching
Life Coaching
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Thank You