→ Value Stream Mapping is an improvement tool which is visualizing the entire process of manufacturing or service representing both material and information flow.
→ It is one of the best Lean Manufacturing Tool as well as Lean Management Tool.
Value Stream Mapping Introduction:
→ T. Ohno from Toyota Production gave the concept of a Value Stream Mapping in 1988.
→ It was introduced as 'Material and Information Flow Mapping’.
→ Later it is named as Value Stream Mapping by John Shook and Mike Rother.
→ Value Stream Mapping puts all the information in one place and it is a very much effective method as compared to other tools like process mapping or any other tools.
→ It is an improvement tool which is visualizing the entire process of manufacturing or service representing both material and information flow.
→ This tool is also used in Six Sigma Projects.
→ This tool is also used in Six Sigma Projects.
➤ What is Value?
→ "Value" is a product or service that the customer is buying.
→ It is a capability to provide a product or a service having the highest quality, at an appropriate price, and at the right time as defined by the customer.
→ Customer’s expectation of value may be, price, quality, reliable delivery, rapid response to changing needs, etc.……
➤ What is a Value Stream?
→ “Value Stream” is to identify the wasteful activity or process from the system and eliminate it from the system.
→ This happens by checking all small activities or process from start to end process which is necessary to convert all input into an output.
→ Value chain refers to all of the activities within an organization.
→ Value chain refers to all of the activities within an organization.
→ While a Value Stream focuses on that activity or process which adds value in a service or in a product.
➤ What is Value Stream Mapping?
→ Value Stream Mapping is a graphical tool that helps us to see and understand the flow of process and information as a product and service.
→ Then you look for opportunities to eliminate or reduce Waste in the process.
→ A value stream usually includes people, tools and technologies, physical facilities, and communication channels, etc...
→ The Value Stream includes value-added activity and non-value added activity throughout the process from start to end.
→ In the majority, the Value Stream Mapping is associated with the manufacturing process.
→ Value Stream Mapping can also be applied in various industries like Product development, Service related industries: e.g. healthcare, insurance, hospitality, and logistics, etc…
→ VSM Study is one of the important in Lean Six Sigma Project.
→ VSM Study is one of the important in Lean Six Sigma Project.
➥ Different things flow through the Value Stream as mentioned below:
→ In manufacturing or distribution, materials flow.
→ Patients flow in health services
→ Information flows in office areas.
→ Internal customer flows in administration.
→ So, in various system service, information, or products flow through a value stream.
→ So, in various system service, information, or products flow through a value stream.
➤ Reason for Value Stream Mapping & Analysis
→ Find out the relationship between process steps
→ We can get information about the current process
→ We can have an actual illustration of the process
→ For setting the improvement targets for the organization
→ Identify improvement opportunity
→ Provide product or service the highest quality, at an appropriate price, and at the right time as defined by the customer
→ Design (concept to a customer)
→ Build (order to delivery)
→ Sustain (in-use through the life cycle to service)
➤ Objectives of Value Stream Mapping:
→ To identify improvement possibility in the process.
→ By eliminating lean wastes from the process and improve the performances of the process.
→ To improve the process efficiency.
→ To improve the process efficiency.
→ Satisfy our customer with our service.
→ Performance improvement of the process.
Team Members of VSM Study Project:
→ Executive Sponsor
→ Process Owner
→ VSM Coach (Facilitator)
→ Workshop/office Participants
➤ Role of the members in VSM
➥ Executive Sponsor:
→ Executive Sponsor is the owner of the Charter
→ He/She decide the team members for the project
→ Executive Sponsor is responsible for ensuring members participation in the project
→ Ongoing project status is presented by the Executive Sponsor.
→ He/She takes part in define the scope, start the project, Active team member of review, audit & follow-ups committee
➥ Process Owner:
→ The process is responsible for the whole process flow.
→ He/She leads the VSM project from beginning to end.
→ Process Owner takes ownership during the VSM event
→ All project meetings, progress, and MOMs are maintained by the Process Owner.
→ Ensures action item pre-work is complete for scoping, workshop/office, and reviews
→ Conduct the review of the implementation plan at a certain interval.
→ He/She gives information to sponsor about the progress of the project.
➥ VSM Coach:
→ VSM coach provides coaching to Process Owner and team.
→ He/She is responsible for defining the scope of the project.
→ Gives training to VSM team and give coaching to the team.
→ VSM Coach gives training on Lean Manufacturing and Lean Process to the team.
→ VSM Coach gives training on Lean Manufacturing and Lean Process to the team.
→ Provide training on lean skills to all participants.
➥ Workshop/office Participants:
→ Participate in the VSM project as a Subject Matter Expert (SME)
→ All Workshop/office Participants are responsible for the process steps.
→ They support the VSM project for successfully run.
→ The group as per project requirement
How to create a Value Stream Mapping?:
→ Value Stream Mapping project should be lead by the expert and can guide other team members for the successful project.
→ The best method of making Value Stream is by hand using a pencil and A3 drawing sheet.
→ During creating the process map all participants should be involved in this activity is always a better decision.
→ Begin with a quick walk along the entire process to process.
→ Begin with a quick walk along the entire process to process.
→ Always trust on your own taken data
→ Map the whole value stream yourself.
Value Stream Mapping Process Steps:
- Gather Data & Information
- Create a Current State Map
- Future State Map & Action Plans
- Execute the Plan
- Align
➤ Step 1 - Gather Data and Information:
→ Gather Information:
→ Define the start & end of the process
→ Define the criteria for data collection
→ Walk and observe the actual workplace and process
→ Take all information related to each and every step.
→ Measure actual lead time, actual cycle time, on-time delivery rate, and defect rate, etc...
➤ Step 2 - Create a Current State Map in VSM Study:
→ Record the detail about the current flow material or information.
→ Make an analysis of the data
→ In the current state of value stream map, we have to mention the actual readings or data of the process.
→ In this stage, we do not have to worry about the future of the process.
→ In this stage, we do not have to worry about the future of the process.
→ We have to mention just as the process is and it should show the real picture of the ongoing process.
→ Then after we can check the possibility of improvement.
→ Then after we can check the possibility of improvement.
➥ VSM Study Symbols:
→ We need to understand the symbols that are using in Value Stream Mapping.
→ There are many symbols used in Value Stream Mapping.
→ The different symbols are used for a different activity that is mentioned in the below picture.
→ By using these symbols we can make a more clear understanding of the process.
→ The different symbols are used for a different activity that is mentioned in the below picture.
→ By using these symbols we can make a more clear understanding of the process.
➥ Collecting Data and Time Studies in VSM Study:
→ The very important step of Creating the Value Stream Mapping is collecting the data.
→ There are a few ways in which we get information.
→ The first, we get the data directly from the industry by contacting all relevant personnel.
→ Take process flow and work instruction data from the company, as well as observed
→ The process in actual, and conduct own time studies to get exact information about the processing time.
→ During the walk carefully observe all process steps and ask as many as possible questions.
→ And collect all data related to that process.
→ And collect all data related to that process.
➥ Some examples of data you should gather in the VSM Study are as follows:
→ No. of work in progress
→ Cycle Times for each process
→ Inspection or testing time
→ Check for the wasteful activity
→ Waiting time and working time etc…
➥ Process Steps in VSM Study:
→ Mention the process flow as actual it is.
→ Write down all process steps in the process box and add all data in this box related to the process
→ Note down inventory days, delay time, wait time, and working time
→ Then calculate all working time and waiting time.
→ Find out the value stream efficiency or Process Cycle Efficiency as calculation mentioned in the below picture.
→ Write down all process steps in the process box and add all data in this box related to the process
→ Note down inventory days, delay time, wait time, and working time
→ Then calculate all working time and waiting time.
→ Find out the value stream efficiency or Process Cycle Efficiency as calculation mentioned in the below picture.
➥ Analysis of the Current State Map in VSM Study:
→ The current state map is a way of saying “what happens now” or the “as-is” process.
→ It should provide all process related information like how the items are being processed and what happens in each step?
→ This information helps us to find out the root cause of problems.
→ So we can improve our process flow by eliminating the root cause.
→ And we can improve the process efficiency, reliability, and flexibility.
→ It should provide all process related information like how the items are being processed and what happens in each step?
→ This information helps us to find out the root cause of problems.
→ So we can improve our process flow by eliminating the root cause.
→ And we can improve the process efficiency, reliability, and flexibility.
➤ Step 3 – Future State Map & Action Plans:
→ Discuss the ideal state
→ Develop the future state map & action plan
→ Build a draft timeline for implementation
→ Communication & training as required
➥ Creating an Ideal and Future State Value Stream Map in VSM Study:
→ Define what we want to achieve the target so that we can focus our efforts on achieving our future State.
→ The expert should create an ideal Value Stream Map which is the best process.
→ The expert should create an ideal Value Stream Map which is the best process.
→ The ultimate goal of your value stream mapping exercise should be approved by senior management.
→ The simplest way to achieve the target is to plan a series of improvements and divide into a various lean event like 5S Methodology, Do-it, Burst, Kaizen Event, and Project.
→ We can highlight the improvement opportunity by using kaizen burst symbol on our current state map.
➥ Analysis of Future State Map in VSM Study:
→ In the future state, map analyzes and reduce the waiting time, so overall time will decrease and performance will increase.
→ By using a Pareto chart or ABC analysis we can easily find our the bottleneck area where we have to work on a priority basis.
→ Then take any of bottleneck process and further analyze on a micro basis, find out the improvement scope and eliminate the Lean Wastes from the process.
➤ Step 4 – Execute the Plan:
→ Implement improvements
→ Conduct Workshops, events, projects, bursts per the implementation plan
→ Achieve value stream objectives
→ Create an environment of Continuous Improvement or Kaizen.
→ During the execution of plan eliminate all wasteful activity from the system or process flow.
→ During the execution of plan eliminate all wasteful activity from the system or process flow.
➤ Step 5 – Align & Analysis of Current State and Future State :
→ Arrange Value Stream Alignment Meeting
→ Periodic basis (based on action plan schedule)
→ Review event implementations & results
→ Evaluate the impact to value stream metrics (individual events and overall)
→ Review next quarter events
→ Inspect changes in a business environment
→ Communicate results
→ Update value stream as required
→ Update implementation plan as required
→ Address resistance and sustainment issues
Keys Points for Successful VSM Study:
→ Select the right person in the VSM project team.
→ Give specific decision-making authority to the team member for the successful project run.
→ All team member give their participants with effectively and efficiently.
→ Always attack the process, Don't attack people
→ Frequently analyze the progress of the project and motivate people for a successful project.
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