Value Stream Mapping (VSM)

 

 Value Stream Mapping

 A visual representation of material and information flows a product from sales order to finished product.

 VSM is diagnostics tools for

•  Distinction between the value add and non- value add activities
•   Shows the linkages between materials and Information flows of a product or process.
•   Forms the basis for an implementation plan.

 The step of VSM

• Define and pick the product or product family.
•   Create current state value stream mapping (CSM).
•   Create future state value stream mapping (FSM).
•   Develop an implementation plan and execution.

Select the product family

•  Start by mapping a large-quantity and high-revenue product family.
•   Product should pass through similar processes and common equipment
•  The analysis is limited to an intra-company focus. (Door-to-door in scope within plant walls)
•  List products within the family

Map the current state

• Gather the data and information using a data log sheet
•  Drawing the current state with a pencil
•   Walk and Understanding how the shop floor currently operates at each process. The foundation for the value state.
•  Define possible "Waste" at each process
•  Prepare the "Data Log Sheet"

Map the current state

Splitting the Mapping

•  Define the process zonage start and end
•  Define at which level next process takes action
•   Use Date and Time at start and end of each process in order to link them back

 

Findings of wastes in different section

• Waiting Time
•   Inventory
•   Defects
•   Transportation
•  Dis-connectivity
•  Excessive Motion

 

Mapping the Future State

• Customer demand phase
•   Continuous flow phase
•   Leveling phase

Creating continuous flow processes

• Line balancing
•   Practicing FIFO
•  Kanban system
•   Supermarket
•   Cellular layout

 

Basie leveling

• Leveling involves evenly distributing the work required tofulfill customer demand over period of time (i.e., month,week, day or hour).
•  Specific measures and techniques used to ensure the smoothness of meeting customer requirements.

Basic leveling tools

• Heijunka Boxes
•   The runner (Mizusumashi)