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03 - Process mapping & Bottleneck Identification - ESTIEM Lean Six Sigma Green Belt Course

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These slides are part of the ESTIEM Lean Six Sigma Green Belt course which also includes 13hr of video by Gregory H. Watson.
For more info about the ESTIEM Lean Six Sigma Green Belt course visit https://internal.estiem.org/leansixsigma

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03 - Process mapping & Bottleneck Identification - ESTIEM Lean Six Sigma Green Belt Course

  1. 1. European Students of Industrial Engineering and Management www.estiem.org Process mapping & Bottleneck identification for publication 1
  2. 2. European Students of Industrial Engineering and Management www.estiem.org It’s Feedback time! 2 Persons giving feedback Link to the feedback form (can be found on Schoology and WhatsApp) Instructor to give feedback toPersons giving feedback INSTRUCTOR 1 INSTRUCTOR 2
  3. 3. European Students of Industrial Engineering and Management www.estiem.org What do you remember about DMAIC? Project Charter SIPOC EDA VA vs. NVA DEFINE Deployment Diagram Identifying the Bottleneck MEASURE 3
  4. 4. European Students of Industrial Engineering and Management www.estiem.org What will we talk about next? Deployment Diagram Mapping the different process steps Identifying the Bottleneck 4
  5. 5. European Students of Industrial Engineering and Management www.estiem.org The output should be several post-its you can move around ... 5
  6. 6. European Students of Industrial Engineering and Management www.estiem.org Three different symbols can be used – activities, decisions, and control points Activity DecisionControl 6
  7. 7. European Students of Industrial Engineering and Management www.estiem.org Simple illustration of the symbols Cut the paper in half Pass?Measure the length Ship the product No Yes Cut the paper in half 7
  8. 8. European Students of Industrial Engineering and Management www.estiem.org Time to work… 8
  9. 9. European Students of Industrial Engineering and Management www.estiem.org SPONSOR MESSAGE 9
  10. 10. European Students of Industrial Engineering and Management www.estiem.org Quiz time! 10
  11. 11. European Students of Industrial Engineering and Management www.estiem.org Question: Why do you differentiate between regular activities and the measuring activity? 11
  12. 12. European Students of Industrial Engineering and Management www.estiem.org Question: Give a practical example of a control and a decision point? 12
  13. 13. European Students of Industrial Engineering and Management www.estiem.org The Deployment Diagram Deployment Diagram Mapping the different process steps Identifying the Bottleneck 13
  14. 14. European Students of Industrial Engineering and Management www.estiem.org What does “to deploy” mean in this context? = How resources are distributed 14
  15. 15. European Students of Industrial Engineering and Management www.estiem.org Simple illustration of the symbols Cut the paper in half Pass?Measure the length Ship the product No Yes Cut the paper in half 15
  16. 16. European Students of Industrial Engineering and Management www.estiem.org What makes it a deployment diagram? Cut the paper in half Pass ? Measure length Ship the product No Yes Person 1 Person 2 Person 3 16
  17. 17. European Students of Industrial Engineering and Management www.estiem.org Time to work… 17
  18. 18. European Students of Industrial Engineering and Management www.estiem.org SPONSOR MESSAGE 18
  19. 19. European Students of Industrial Engineering and Management www.estiem.org Quiz time! 19
  20. 20. European Students of Industrial Engineering and Management www.estiem.org Question 1/3: Why is it important to map the different steps of the process? 20
  21. 21. European Students of Industrial Engineering and Management www.estiem.org Question 2/3: What could be problematic in setting up the deployment diagram? 21
  22. 22. European Students of Industrial Engineering and Management www.estiem.org Question 3/3: How are SIPOC maps and deployment diagrams linked to each other? 22
  23. 23. European Students of Industrial Engineering and Management www.estiem.org Identifying the Bottleneck Deployment Diagram Mapping the different process steps Identifying the Bottleneck 23
  24. 24. European Students of Industrial Engineering and Management www.estiem.org First of all, some definitions… 24
  25. 25. European Students of Industrial Engineering and Management www.estiem.org What is the difference between push and pull production? 25
  26. 26. European Students of Industrial Engineering and Management www.estiem.org Push = production is done towards the individual targets (production plan), can be produced to stock Pull = production is started only when the next process step demands a product 26
  27. 27. European Students of Industrial Engineering and Management www.estiem.org What are the problems with the push production? 27
  28. 28. European Students of Industrial Engineering and Management www.estiem.org Push production can lead to waste by … • Excess inventory (e.g. tied working capital, inventory costs…) • Hides inefficiencies in the process • Increases the detection time of defects • … … … … 28
  29. 29. European Students of Industrial Engineering and Management www.estiem.org The optimal state is often referred to as having a good ”flow”. What do we mean by the ”flow” in a production line? 29
  30. 30. European Students of Industrial Engineering and Management www.estiem.org Flow = how the work progresses in the process Good flow = work progresses steadily and predictably through the process 30
  31. 31. European Students of Industrial Engineering and Management www.estiem.org What do we mean by takt time? 31
  32. 32. European Students of Industrial Engineering and Management www.estiem.org Takt time = customer order rate, i.e. (available time) / (number of orders) 32
  33. 33. European Students of Industrial Engineering and Management www.estiem.org What is the difference between lead time and cycle time? 33
  34. 34. European Students of Industrial Engineering and Management www.estiem.org Throughput time = the time it takes to go through the production Cycle time = the time taken by one process step 34
  35. 35. European Students of Industrial Engineering and Management www.estiem.org 0, 1,5 3, 4,5 6, 7,5 Step 1 Step 2 Step 3 Step 4 Step 5 Identify takt, cycle and lead time Time (min) 35
  36. 36. European Students of Industrial Engineering and Management www.estiem.org 0 1 2 3 4 5 6 7 Step 1 Step 2 Step 3 Step 4 Step 5 Takt time Cycle Time Time (min) Identify takt, cycle and lead time Waiting ? = Lead time 36
  37. 37. European Students of Industrial Engineering and Management www.estiem.org What do we mean by ”Bottleneck”? 37
  38. 38. European Students of Industrial Engineering and Management www.estiem.org What is the effect of the Bottleneck? 38
  39. 39. European Students of Industrial Engineering and Management www.estiem.org 0, 1,5 3, 4,5 6, 7,5 Step 1 Step 2 Step 3 Step 4 Step 5 Takt time What happens if you improve the step 3? 39
  40. 40. European Students of Industrial Engineering and Management www.estiem.org 0, 1,5 3, 4,5 6, 7,5 Step 1 Step 2 Step 3 Step 4 Step 5 Takt time How do we call the ”step 5”? 40
  41. 41. European Students of Industrial Engineering and Management www.estiem.org 0, 1,8 3,5 5,3 7, Step 1 Step 2 Step 3 Step 4 Step 5 Takt time Where is the bottleneck now? 41
  42. 42. European Students of Industrial Engineering and Management www.estiem.org 1 2 3 4 5 6 107 8 9 1112 Variation reveals new aspects! Which chart is best for bottleneck identification? 42
  43. 43. European Students of Industrial Engineering and Management www.estiem.org Quiz time! 43
  44. 44. European Students of Industrial Engineering and Management www.estiem.org Question: How do the following terms link together: 1) Lead time 2) Takt time 3) Cycle time 4) Bottleneck 44
  45. 45. European Students of Industrial Engineering and Management www.estiem.org Question: Why is it important to pursue good flow in a production line? 45
  46. 46. European Students of Industrial Engineering and Management www.estiem.org Time to work… 46
  47. 47. European Students of Industrial Engineering and Management www.estiem.org SPONSOR MESSAGE 47
  48. 48. European Students of Industrial Engineering and Management www.estiem.org How was the recording of the data? What did you recognize? 48
  49. 49. European Students of Industrial Engineering and Management www.estiem.org Thank you for your attention! 49
  50. 50. European Students of Industrial Engineering and Management www.estiem.org It’s Feedback time! 50 Persons giving feedback Link to the feedback form (can be found on Schoology and WhatsApp) Instructor to give feedback toPersons giving feedback INSTRUCTOR 1 INSTRUCTOR 2
  51. 51. European Students of Industrial Engineering and Management www.estiem.org It’s Feedback time! Feedback box 51
  52. 52. European Students of Industrial Engineering and Management www.estiem.org Usage license of the materials https://creativecommons.org/licenses/by-nc/4.0/legalcode Contact leansixsigma@estiem.org for commercial usage of the materials Materials of the trainings have been created based on the materials provided by ESTIEM Summer Academy Professor Gregory H. Watson

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