Value Stream Mapping

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Value Stream Mapping

• A tool originally used by the Toyota Production System experts to study processes

• Developed and refined by John Shook and Mike Rother

• Used in manufacturing, engineering and administrative offices by lean experts to improve business processes

Value Stream Mapping Definition

– Special type of flow chart that uses symbols known as "the language of Lean" to depict and improve the flow of inventory and information.

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What is a Value Stream?

A value stream involves all the steps, both value added and non value added, required to complete a product or service

from beginning to end

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Value Stream Improvement & Process Improvement

Value Stream

Improvement

PROCESS PROCESS PROCESS

Outgoing Finished Product

Incoming Raw Materials

Customer

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PURPOSE :

Understand the role value stream mapping plays in continuous improvement

Draw a current-state map

Draw a future-state map

Develop an implementation plan

Getting Started

Using the Value Stream Mapping Tool

Understanding how things

currently operate. This is

the foundation for the

future state.

Scoping the

Value Stream

Designing a lean flow through

the enterprise.

Future state

drawing

Determine the Value

Stream to be improved

The goal of mapping! Planning and

Implementation

Current state

drawing

Advantage of Value Stream Mapping & Analysis

• Develop a common understanding of the current process– The relationship of process steps

– A true picture of the process

• Create a baseline to measure improvements against

• Define a vision of the future process

• Establish common leadership objectives

• Identify opportunities for improvement

• Design an implementation plan for improvements

“If you can’t describe what you are doing as a process, you don’t know what you’re doing.” W. Edwards Deming

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Planning tool to optimize results of eliminating waste

Analyzing the Value Stream

+ + =Lean

Basics

current state VSM future state VSM

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A SIMPLE EXAMPLE…………..

Pick Up Paper Walk to Stapler Staple Paper

Walk to Desk Put Down Paper

Time: 1 sec.Distance: 0

Time: 5 sec.Distance: 20 ft.

Time: 5 sec.Distance: 20 ft.

Time: 2 sec.Distance: 0

Time: 1 sec.Distance: 0

Total Time: 14 sec.Total Dist: 40 ft.Value Added Time: 4 sec.Value Added Dist: 0

Value Added Time: 28%

Info: Where to place stapleInfo: Location of stapler

Excess Travel

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The Current State Map

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Sample VSM Map

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Value Stream Mapping Symbols

VSM Symbols

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Current State Drawing

Current State

Product Family

Current State Drawing

Future State Drawing

Plan and Implementation

Determining how production currently operates.

Material and Information flows

Draw using VSM icons

Start with the “door to door” flow

Walk the production lines and get actualsNo standard timesDraw by hand, with pencil

Foundation for the Future Site

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TAKT Time

TAKT Time

Match assembly pace to pace of orders.

Rate for assembling based on orders rate.

Work Time per ShiftTAKT Time =

Customer Requirement per Shift

27,600 sec

460 pieces= 60 seconds

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Future State Value Stream

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Future State Drawing

Future State

Product Family

Current State Drawing

Future State Drawing

Plan and Implementation

Designing a LEAN Flow

The power behind Value Stream Mapping is you always need a future state!

Keep Updating. Use pencil!

Material and Information flows

Basis for your Work Plan – like a “blueprint”

Begin by drawing on Current State

1st iteration assumes existing steps & equipment

Can move equipment, combine, take outconveyors, make minor purchases etc.

But, there is a Problem!

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Future State Map

Future State

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