Applying Value Stream Mapping (VSM) Applying Value Stream Mapping (VSM) Tool to Improve Annual Plant Aerosol Tool to Improve Annual Plant Aerosol

Mapping ProcessMapping Process

Maria PryorMaria PryorSr. Industrial HygienistSr. Industrial Hygienist

General MotorsGeneral Motors

What Is Aerosol What Is Aerosol --and Why do we Care?and Why do we Care?

Metal Removal Fluids (Metal Removal Fluids (MRFsMRFs) are used as coolants and/or cutting oils) are used as coolants and/or cutting oils

MRF Aerosols are generated during the machining processMRF Aerosols are generated during the machining process

High levels of MRF Aerosol are associated with lung function chaHigh levels of MRF Aerosol are associated with lung function changes nges and increased risk of asthma. Exposure to mist is also associatand increased risk of asthma. Exposure to mist is also associated ed with hypersensitivity with hypersensitivity pneumonitispneumonitis, a serious lung disease., a serious lung disease.

OSHA has set a Permissible Exposure Limit for MRF Aerosol is 5 OSHA has set a Permissible Exposure Limit for MRF Aerosol is 5 mg/m3, based on eight hours of worker exposure.mg/m3, based on eight hours of worker exposure.

The GM Occupational Exposure Guideline is 1 mg/m3. The GM Occupational Exposure Guideline is 1 mg/m3.

GM GM PowertrainPowertrain Specifications call for new equipment to meet 0.5 Specifications call for new equipment to meet 0.5 mg/mmg/m33..

GM and the UAW have done a lot of work to reduce MRF Aerosol.GM and the UAW have done a lot of work to reduce MRF Aerosol.

What is an Aerosol Map?What is an Aerosol Map?

ItIt’’s a tool, and a picture.s a tool, and a picture.MRF Aerosol levels are MRF Aerosol levels are overlayedoverlayed onto a plant onto a plant layout.layout.It doesnIt doesn’’t tell you who is t tell you who is overexposed. overexposed. It does show you where the It does show you where the ““hot spotshot spots”” are, and where are, and where to focus engineering efforts to focus engineering efforts to improve. It can also show to improve. It can also show yearyear--toto--year changes.year changes.

Long lead time for aerosol mapLong lead time for aerosol map

Too many handToo many hand--offs for report creationoffs for report creation

Timing of report and map delivery Timing of report and map delivery asynchronousasynchronous

Need more standardized elements in processNeed more standardized elements in process

Need to reduce resources requiredNeed to reduce resources required

Need to improve logisticsNeed to improve logistics

Why Improve the Current Process?Why Improve the Current Process?

Value Stream Map (VSM) ToolValue Stream Map (VSM) Tool

A Value Stream Map (VSM) involves all the A Value Stream Map (VSM) involves all the steps, both value added and nonsteps, both value added and non--value value added, required to complete a product or added, required to complete a product or service from beginning to end.service from beginning to end.

It makes the process more visual in order to It makes the process more visual in order to identify hidden wastes.identify hidden wastes.

It shows bottlenecks, rework or waiting that It shows bottlenecks, rework or waiting that affect the flow of the product or service.affect the flow of the product or service.

Leadership PanelVSM TeamVSM Team

Workshop Participants

GMS CoachesCoaches in TrainingCoach:

Director, Chemical Risk ManagementManager, Industrial Hygiene & ToxicologyManager, Industrial HygieneSr. Manager, Health & SafetyManager, Divisional Health & SafetyResearch & Development

Sr. Industrial HygienistSr. Industrial HygienistSr. Industrial HygienistSr. Industrial HygienistResearch Engineer

Purpose StatementPurpose Statement

•• Aid GMAid GM’’s efforts to reduce worker exposure to MRF aerosolss efforts to reduce worker exposure to MRF aerosols•• Reduce resources required for mappingReduce resources required for mapping•• Improve quality of deliverables (map & report)Improve quality of deliverables (map & report)•• Reduce lead timeReduce lead time•• Reduce associated costsReduce associated costs•• Improve map production & data collectionImprove map production & data collection•• Aid GMAid GM’’s efforts to prevent pollution at sources efforts to prevent pollution at source

Project Objectives

Project Description

To improve the efficiency of GM’s plant aerosol source mapping process

Decide Sample Points

1

Prepare MappingHandouts

1

Aerosol Mapping Process Current State MapAerosol Mapping Process Current State Map

P/T = 1-5 days

FTQ = 75%

Data Entry into Excel

1

Data Processing

1

Set up PlantGrid

1

Export data toDeltaGraph

1

Map Production in DeltaGraph

1

Final Map Print& Ship

1

Add Dummy Points

1

I IIIIII

2 0 00 0 00Secure Plant Layout CAD

1-3

Aerosol Mapping Team

WFG ES Chem. Mgmt. Industrial Hygiene

UAW

Deliverables

• Aerosol Map• Yearly data comparison• Mapping Report• PSRB Presentation

Research & Development

YearlyScheduleYearly

Schedule

CentralLayout

PlantIE/PE

LeadI.H.

Request Plant layout CAD

Data Sheets

PlantI.H.T.

Data Sheets

Research EngineerYearly

Schedule

Day of Mapping

P/T = 1 day

FTQ = 90%

P/T =1 day

FTQ = 85%

P/T = 1-3 days

FTQ = 70%

P/T =2 days

FTQ = 90%

P/T =0.5 day

FTQ = 90%

P/T =0.5 day

FTQ = 90%

P/T =5 min

FTQ = 99%

P/T =1 day

FTQ = 90%

P/T =0.25 day

FTQ = 95%

P/T =0.5 day

FTQ = 90%

YearlySchedule

Type Observations

1-9

Pool Obs. &Make Report

1

II0

P/T = 60 min

FTQ = 90%

P/T =10 min

FTQ = 99%

P/T = 1 day

FTQ = 90%

0

60 min 1 day10 min

01-10 days

Aerosol Maps Database

Send Obs.To Lead I.H.

1-9

Maintain & Update

Data Sheets

CollectAerosol Data

1-9

ShipReport

1

P/T = 30 min

FTQ = 99%

0

30 min

3 days

Sid Kinare, Sandeep PavnaskarAerosol Map VSM Team:Jim D’Arcy, Jim Griffin, Dave ThorpeMaria Pryor, Bob Chapman, Graham ParrAugust 10, 2004

Prepared by

NJC,Div. Board

Plant

PE, ME

WFG

20%20%Value added ratioValue added ratio

22.30447%22.30447%FTQFTQ

6 days6 daysNet value added timeNet value added time

15 days15 daysNet cycle timeNet cycle time

30 days30 daysTotal lead timeTotal lead time

Data Sheets

I

One way information flowOne way information flow

Two way information flowTwo way information flow

Work document generatedWork document generated

InventoryInventory

# of operators# of operators

Iterative workIterative work

First Time QualityFirst Time QualityFTQFTQ

Value added process timeValue added process timeP/TP/T

InterpretationInterpretationIconIcon

LegendLegend

Iteration

I

Iteration

Iteration

Iteration

Iteration

3 days005 days 00 0 000 0-2 days

1 – 3 days 0.25 day0.5 day2 days 1 day0.5 day5 min0.5 days1-5 days 1 day1 day

Iteration

Yearly Aerosol Mapping Review

Communicate with Team

Secure instruments

Calibrate instruments

Pool data sheets

Out of scopeDevelop Master schedule for Develop Master schedule for contract periodcontract period

Standardize data collection Standardize data collection sheets for all plantssheets for all plants

Standardization of report Standardization of report elementselements

Reduce data collection runs Reduce data collection runs for nonfor non--production areasproduction areas

Develop Develop ““aerosol mapperaerosol mapper””training moduletraining module

Identify and increase qualified Identify and increase qualified ““mappermapper”” poolpool

Pilot aerosol map production Pilot aerosol map production & deployment using software & deployment using software

Develop an electronic data Develop an electronic data collection systemcollection system

Pilot electronic data collectionPilot electronic data collection

Automate the mapping reportAutomate the mapping report

Secure funding for Secure funding for continuous improvements continuous improvements

Annual aerosol maps reportAnnual aerosol maps report

Data analysis and statistics Data analysis and statistics

Migration of historical aerosol Migration of historical aerosol maps into softwaremaps into software

In scopeIn scope

Aerosol Mapping Process Future State MapAerosol Mapping Process Future State Map

57.14285%57.14285%Value added ratioValue added ratio

69.04125%69.04125%FTQFTQ

13 days13 daysNet value added timeNet value added time

13 days13 daysNet cycle timeNet cycle time

14 days14 daysTotal lead timeTotal lead time

Sid Kinare, Robin RicheyAerosol Map VSM Team:Jim D’Arcy, Jim Griffin, Dave ThorpeMaria Pryor, Bob Chapman, Graham ParrSeptember 10, 2004

Prepared by

Continuous Improvements

Aerosol Maps Database

CollectAerosol Data

1-9- DustTrak-Paper

Mapper

P/T = 1-3 days

W/T = 0 days

FTQ = 85%

Pool data into Template;

Email to R&D

1- Std. PlantTemplate

Lead IH

P/T = 1 day

W/T = 1 days

FTQ = 95%

Input data & comments; Email to IH

1-9- Std. PlantTemplate

Mapper

P/T = 1 day

W/T = 0 days

FTQ = 95%

Prework & Review

1-2- Std. PlantTemplate

Lead IH, IHT

P/T = 1 day

W/T = 0 days

FTQ = 100%

Generate Report

1- Std. ReportFormat

Lead IH

P/T = 1 day

W/T = 0 days

FTQ = 90%

Upload data into GIS

Map Template

1- Excel - ArcGIS

R&D

P/T = 2 days

W/T = 0 days

FTQ = 90%

Ship 2 CD’s(map & report)to IH

1

R&D

P/T = 3 days

W/T = 0 days

FTQ = 100%

I

0

I

0

I

0

I

0

Mapping report

Deliver 1 CD to Plant

1- ArceRader- PDF

Lead IH

P/T = 1 day

W/T = 0 days

FTQ = 85%

Deliverables• Aerosol Map• Mapping ReportPlant

PlantIHT

2

1

Update Metric Sheet; Email to IH

Manager1- Excel

R&D

P/T = 1 days

W/T = 0 days

FTQ = 100%

WFG – IH

IH Manager

P/T = 1 day

W/T = 0 days

FTQ = 100%

Review next year’s mapping schedule and

resources(late November)

PT IE Central Layout

Secure yearly updated Plant Layout CAD(late April)

R&D

P/T = N/A

W/T = N/A

FTQ = N/A

Email reminder of current year’s

mapping schedule

(early January)

IH Manager

P/T = N/A

W/T = N/A

FTQ = N/A

WFG - IH

Trigger –yearly schedule Checkpoint

Checkpoint

One way information flowOne way information flow

Two way information flowTwo way information flow

Work document generatedWork document generated

InventoryInventory

# of operators# of operators

First time qualityFirst time quality

Wait timeWait timeW/TW/T

Value added process timeValue added process timeP/TP/T

InterpretationInterpretationIconIcon

LegendLegend

I

FTQFTQ

Maintain & Update

Key Characteristics of the Future StateKey Characteristics of the Future State

Master schedule Master schedule

More efficient management of resources and logisticsMore efficient management of resources and logistics

Standardized data collection sheets for all plantsStandardized data collection sheets for all plants

Process triggers and checkpoints in placeProcess triggers and checkpoints in place

Production and deployment of electronic aerosol maps Production and deployment of electronic aerosol maps

Timely delivery of aerosol map and report on CDTimely delivery of aerosol map and report on CD

Implementation PlanImplementation Plan

Develop master scheduleDevelop master schedule

Develop tracking spreadsheets for costs, logistics, and Develop tracking spreadsheets for costs, logistics, and resourcesresources

Standardize data collection protocol, spreadsheets and Standardize data collection protocol, spreadsheets and report formatreport format

Develop aerosol map template for all plantsDevelop aerosol map template for all plants

Standardize electronic production and deployment of Standardize electronic production and deployment of aerosol mapsaerosol maps

Business Plan Deployment (BPD)Business Plan Deployment (BPD)

Current State BPD Future State

ResultsResults

SafetySafety–– Enhance engineering response to areas of Enhance engineering response to areas of

concern reducing overall worker exposure concern reducing overall worker exposure to aerosol mistto aerosol mist

PeoplePeople–– Reduce resources required for yearly Reduce resources required for yearly

mapping by 40% (120 days to 70 days)mapping by 40% (120 days to 70 days)

QualityQuality–– Aerosol map and report delivered in a Aerosol map and report delivered in a

timely fashion timely fashion

ResponsivenessResponsiveness–– Reduce lead time from 30 days to 14 daysReduce lead time from 30 days to 14 days

ResultsResults

CostCost–– Reduce travel cost by 50%Reduce travel cost by 50%

TechnologyTechnology–– Production and deployment of electronic aerosol Production and deployment of electronic aerosol

maps using special softwaremaps using special software

ResultsResults

Continuous ImprovementsContinuous Improvements

Pilot electronic data collection Pilot electronic data collection

Develop scripts for automated report generationDevelop scripts for automated report generation

Migration of all historical aerosol maps into software Migration of all historical aerosol maps into software packagepackage

Data analysis and spatial statistics using historical mapsData analysis and spatial statistics using historical maps

Pilot project to overlay plant people locations, ASP, Pilot project to overlay plant people locations, ASP, ventilation, etc. onto aerosol mapventilation, etc. onto aerosol map