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Process Design and Visual Value Streams

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Business process design, notwithstanding the type of business, follows steps that are all encompassing of meeting the business needs. Process visual management is then designed to ensure this design is working and continuously improving.

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Process Design and Visual Value Streams

  1. 1.  Robert Baird President +1 215 353 0696 The 2nd Component Process Design and Visual Value Streams 29-Dec-15 www.leanteamsusa.com
  2. 2. 29-Dec-15 www.leanteamsusa.com 2
  3. 3. Process Design Criteria www.leanteamsusa.com 3 Customer Requirements Capability Demand (Current and Future) Lead Time Layout Flow Cellular design, Product design, or Process design People Required skills Number Support departments Equipment Automation DFOEE – Design For Overall Equipment Effectiveness Support (tables, measurement, IT, security, material handling) Facility Location Energy Structure Health Safety Environment Ergonomics, Equipment Safety, Prevention Hazardous materials
  4. 4. Process Design Tools • Computer Aided Design (CAD) • Flowchart • Value Stream Mapping (VSM) • Supplier Input Process Output Customer (SIPOC) • Spaghetti Map • Process statistical software 29-Dec-15 www.leanteamsusa.com 4
  5. 5. Process Design Steps 1. Business need statement 2. Establish process design team 3. Outline of customer demand and requirement 4. Facility review 5. Layout design 6. Equipment requirements 7. People requirements 8. Health, Safety, and Environment requirements 29-Dec-15 www.leanteamsusa.com 5
  6. 6. 29-Dec-15 www.leanteamsusa.com 6
  7. 7. www.leanteamsusa.com 7 0.00 4.00 8.00 12.00 16.00 Task Cycle Time Required Takt Time = 14.98 Sec Thickness 10.5 mm Color 3.5 Delta E Yield 99.05% Yield 99.75% X-Y Position Pressure Units Out 5,300/day Thickness Heat Yield 99.75% Units Out 5,300/day Units Out 5,300/day Yield 99.995% WIP 1800 Units WIP 1700 Units WIP 1700 Units Heat Height Viscosity Pressure 3 SIGMA 3 SIGMA 4 SIGMA 4 SIGMA Processes Step1 Step 2 Step 3 Step 4 System Scheduled Time (seconds) 79,207 79,207 79,207 79,207 Throughput (Units/hour) 300 280 342 400 Inventory Time (Hour) 6 6 5 4 Process Lead Time (Hour) 22 Process Yield 99.50% Process Throughput (Units/hour) 280 Mth. Sales forecast (Units) 121,600 Days in month 23
  8. 8. 29-Dec-15 8www.leanteamsusa.com
  9. 9. Visual Management Rules ALL MUST BE SATISFIED • 80:20 Manual: Automated data collection  Simple and Affordable • Real time measures • Must provide value  Value Stream Workers  Leadership team • Must inspire conversation in the Gemba • 80:20 Input measures: Output measures • Preventative measures (Inputs)  Quality  Capability  Safety • Provides results of intended design (Outputs) • Clear indication of continuous improvement and the HOW 29-Dec-15 9www.leanteamsusa.com
  10. 10. Contact Us • Lean Teams USA Lean Consulting • View My Profile on LinkedIn • Lean Teams USA +1 215 353 0696 • Link to 3rd Component 29-Dec-15 www.leanteamsusa.com 10

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