Value Stream Mapping to Create Value and Eliminate Muda
Value-Stream Mapping toCreate Value and Eliminate Muda Presented by Mohammed El Boussami Hafez Shurrab
IntroductionSupply Chain Seven wastes Value Stream Mapping
Why Value Stream Mapping• Information & materials relation• Identify Wastes• Continuous Improvement
Five Steps to do Value Stream Mapping• Product Family• Current State Map• Future State Map• Plan• Value Stream Map
CASE STUDY: ACME STAMPING & WIRE FORMING CO.• Acme has been incorporated in 1921• Metal Stamping, CNC Machining, & Wire Forming• Mass Prodcution & Push Systems• Lean Manucaturing & Pull
The data of Acmes Production Processes Cycl WIP next to the process e Changeove Uptim Process Time r Time e (%) (sec. (sec.) (unit), L: lift, (D): Day of ) R: right DemandStamping 1 3600 85 4600 L - 2400 R 7.6 DWelding “1” 39 600 100 1100 L - 600 R 1.8 D Welding 46 600 80 1600 L - 850 R 2.7 D “2”Assembly 62 - 100 1200 L - 640 R 2D “1”Assembly 40 - 100 2700 L - 1440 R 4.5 D “2”
Guiding Questions• What is the takt time of Acme for the selected product family?• Should Acme build steering brackets directly to shipping or to a finished goods supermarket/buffer?• Where could continuous flow be introduced?• Where buffers would be set?• What the pacemaker process?• How should Acme level the production mix?• What consistent increment of work should be released?• What process improvements will be necessary?
Load-Leveling Boxshift 1 7 720 740 8 820 840 910 930shift 2 4 420 440 5 520 540 610 630Left L L L L LDriveRight R R RDrive
Acme Stamping Lead-Time Improvement Producti TotalLocatio Stamped Wie/Ass. Finished Coil on Lead Inventor n Parts WIP Goods Time y Turns Before 5 Days 7.5 Days 6.5 Days 4.5 Days 23.6 Days 10Continuous Flow & 2 Days 1.5 Days 0 4.5 Days 8 Days 30 Pull With 1.5 Days 1 Day 0 2 Days 4.5 Days 53 Leveling
Conclusion• VSM is highly recommended tool to eliminate muda.• There should be high cooperation between all business owners in the supply chain.• VSM guides to which tools and practices could be effeciently incorporated.• Kaizen targets should be given high priorities.• VSM could be also helpful for intelligent benchmarking.
Conclusion (cont.)• Some concerns are: The diversity of indusries characteristics Technological limits Resistance to change The accessibility of data