Process Mapping and Waste.ppt

7/25/2019 Process Mapping and Waste.ppt

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THE SEVEN CLASSESTHE SEVEN CLASSES

OF WASTEOF WASTE What is Waste?What is Waste?

Value for Whom?Value for Whom?

Find and Eliminate Waste.Find and Eliminate Waste.

SS


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#1 Excess Production#1 Excess Production

ExamplesExamples________________________________________________________________________________________________________

Excess production !ides pro"lemsExcess production !ides pro"lemsand createsand creates:: Extra inventory, handlin, e!ui"ment usae,Extra inventory, handlin, e!ui"ment usae,

s"a#e, !uality "ro$lem issues, et#.s"a#e, !uality "ro$lem issues, et#.

Production s!ould "e determined "Production s!ould "e determined "t!e customer$ not %&alse tar'ets(t!e customer$ not %&alse tar'ets(

suc! as utili)ationsuc! as utili)ation..


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#* Waitin' or Watc!in'#* Waitin

' or Watc!in'

CausesCauses Waitin' &or +aterialsWaitin' &or +aterials

Waitin' &or E,uipment-ToolsWaitin' &or E,uipment-Tools Waitin' &or .epairs-Ser/iceWaitin' &or .epairs-Ser/ice

Waitin' &or Lar'e Lots to Finis!Waitin' &or Lar'e Lots to Finis!

Watc!in' 0nrelia"le ProcessesWatc!in' 0nrelia"le Processes

Watc!in' &or Pro"lemsWatc!in' &or Pro"lems

E&&ectsE&&ects Wastes TimeWastes Time


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# Con/eance or# Con/e

ance or

TransportationTran

sportation CausesCausesPoor LaoutsPoor Laouts 2Lon' distances2Lon' distances

"et3een process operations4"et3een process operations4

Lar'e Production LotsLar'e Production Lots

5atc! Processes5atc! Processes

Poor Sc!edulin'Poor Sc!edulin'



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#6 Processin' 7tsel Processin

' 7tsel&

CausesCausesPoorl +aintained E,uipmentPoorl +aintained E,uipment

7mproper- Poor Toolin'7mproper- Poor Toolin'Excess C!ec8in'-Stoppin'Excess C!ec8in'-Stoppin'

7mproper +aterials7mproper +aterials

Errors in Processin'-SetupErrors in Processin'-SetupPoor-no Wor8 7nstructionsPoor-no Wor8 7nstructions



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#9 7n/entor#9 7n/entor

CausesCauses Lon' SetupsLon' Setups

Lar'e 5atc! Si)esLar'e 5atc! Si)es %%+indset( o& Com&ort+indset( o& Com&ort

.eliance on %+.P( to reorder.eliance on %+.P( to reorder

5atc! Processin'5atc! Processin'

E&&ectsE&&ects Wastes Time : HidesWastes Time : Hides.eal Pro"lems.eal Pro"lems 2,ualit$ sc!edulin'$2,ualit$ sc!edulin'$suppliers$ maintenance$ attendance$ etc;4suppliers$ maintenance$ attendance$ etc;4


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#< +otion#< +otion

CausesCausesPoor Laouts : FacilitiesPoor Laouts : Facilities

Poor Wor8 Place =esi'nsPoor Wor8 Place =esi'ns %%Lost 7tems-Searc!in'Lost 7tems-Searc!in'

Lac8 o& Needed Toolin' :Lac8 o& Needed Toolin' :

E,uipmentE,uipment E&&ectsE&&ects Wastes TimeWastes Time


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#> Producin' Failures#> Producin' Failures

CausesCauses Poor Trainin'Poor Trainin'

Poor +anu&acturin' 7nstructionsPoor +anu&acturin' 7nstructions Poor E,uipment : Toolin'Poor E,uipment : Toolin'

Poor +aterialsPoor +aterials

???????????????????????????????????????????????????????????????? E&&ectsE&&ects Wastes TimeWastes Time


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Ho3 to 7denti& andHo3 to 7denti& and

Tar'et Waste 3it! @ai)enTar'et Waste 3it! @ai)en

You cant eliminateYou cant eliminate

what you dont see.what you dont see.


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%dd Value?%dd Value?

Supplier

Internal or

External

Work

Station

Process

Customer

Internal or

External

PROCESS MODELPROCESS MODEL


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C0STO+E. FOC0SC0STO+E. FOC0S

E%&' ()*&ESS '%S +S *W-E%&' ()*&ESS '%S +S *W-

S((/+E) %-0 &S*1E).S((/+E) %-0 &S*1E).

ltimate or external #ustomer.ltimate or external #ustomer. +mmediate or internal #ustomer.+mmediate or internal #ustomer.

0efine and understand your #ustomer2s0efine and understand your #ustomer2sneeds and ex"e#tations.needs and ex"e#tations.


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WHO A.E O0.WHO A.E O0.

C0STO+E.SBC0STO+E.SBW'* %)E 3*) /+1%E &S*1E)S?W'* %)E 3*) /+1%E &S*1E)S?

W'* %)E 3*) +11E0+%EW'* %)E 3*) +11E0+%E&S*1E)S:&S*1E)S:

W'% %)E 3*)W'% %)E 3*)&S*1E)2S -EE0S, )E4+)E1E-S,&S*1E)2S -EE0S, )E4+)E1E-S,

%-0 E5(E&%+*-S:%-0 E5(E&%+*-S:


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+ANA7N 0PST.EA++ANA7N 0PST.EA+

Effe#tive "ro#ess fo#us re!uires you to oEffe#tive "ro#ess fo#us re!uires you to o

$a#6 to the "revious "ro#ess to see6 out$a#6 to the "revious "ro#ess to see6 out

a "ro$lem2s #auses.a "ro$lem2s #auses.

+m"rovement re!uires that 7e al7ays $e+m"rovement re!uires that 7e al7ays $e

a7are of 7hat #omes from the "reviousa7are of 7hat #omes from the "revious"ro#ess. 8Su""lier9."ro#ess. 8Su""lier9.


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=e&inin' Process Flo3=e&inin' Process Flo3

sese VisualVisual"ro#ess ma""in#hartin"ro#ess ma""in#hartinte#hni!ues:te#hni!ues: (ro#ess &harts for (rodu#ts(ro#ess &harts for (rodu#ts Flo7 &harts for SystemsFlo7 &harts for Systems

Fun#tional 0e"loyment 1a" for %#tions andFun#tional 0e"loyment 1a" for %#tions andFun#tionsFun#tions

Value Stream 1a"s 8VS19 for 1aterials andValue Stream 1a"s 8VS19 for 1aterials and+nformation+nformation

Define and understand your processes to

identify and eliminate waste.


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()*&ESS &'%)S()*&ESS &'%)S

%id in%id in::

Visuali;in and understandin the "ro#essVisuali;in and understandin the "ro#ess

+dentifyin s"e#ifi# o"erations for im"rovement+dentifyin s"e#ifi# o"erations for im"rovement

nderstandin effe#ts of #hanes in one ste" on othersnderstandin effe#ts of #hanes in one ste" on others

(ur"oses(ur"oses::

)edu#e o"eratormaterial movement)edu#e o"eratormaterial movement

*rder a#tivities "ro"erly*rder a#tivities "ro"erly


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+. (ro#ess &hart+. (ro#ess &hart

=details all 7or6 done $y or on one "rodu#t=details all 7or6 done $y or on one "rodu#t

Symbol Action Classification Predominant Result

Operation

Transportation

Inspection

Delay

Storae

Produces or Accomplis!es

"o#es

$erifies

Interferes

%eeps


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Operation Process C!art s!owin intensity of material flow and t!e out&flow of c!ips and scrap '"ut!er( R. Systematic Layout

Planning. C)I Publis!in Company( Inc.( )oston( *+,-.

Castin S!eet Steel

Storae

)olts

- Tons Turnins

/.- Tons

Turnins

/.- Tons

-.- Tons

Turn

0 Tons

/&1

/&0 /&*

/&2

/&-

/&3

Scrap

2 Tons

Offal

* TonDrill

, Tons

- Tons

+ Tons

)lan4

+ Tons

Trim

*/.1 Tons

Assemble5

Inspect

6orm


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7ori8ontal line indicates material feedin

into process

$ertical line indicates steps of process

arraned in c!ronoloical se9uence

A.


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). 7ori8ontal lines i#e way w!en lines cross

"aterial in&feed line

Process se9uence line


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C. Typical process diaram

Symbol and :umber

Time5Place Description

Paint/./20/

Test2

0


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D. Assembly wor4 c!artin starts in upper ri!t corner of

s!eet wit! larest component or one !a#in most

operations.

Purc!ased item

or material


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E. Alternate routins s!own by split and re;oined lines

*

2

1

0

-


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6. "aterial returned for rewor4

*

-


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7. Complex c!arts aided by arrows( cur#ed corners

*

3

,

2


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()*()*

%+0E%+0E%naly;e the #hart usin the 4uestionin %ttitude: 0oes%naly;e the #hart usin the 4uestionin %ttitude: 0oes

the a#tivity add value for the #ustomer?the a#tivity add value for the #ustomer?

+F -* +F -*

0etermine ho7 #an a#tivities $e:0etermine ho7 #an a#tivities $e:

Eliminated?Eliminated?

Sim"lified?Sim"lified?

&haned in se!uen#e?&haned in se!uen#e? &om$ined?&om$ined?

Standardi;ed?Standardi;ed?


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F/*W&'%)SF/*W&'%)S

A flowc!art is a pictorial representation of a loical decision process( w!ic! identifies

all of t!e ma;or steps and decision points in#ol#ed in proressin from t!e beinninto t!e end.

6lowc!arts pro#ide a lobal o#er#iew of a >procedure?

clearly identifyin !ow eac! step is related to t!e ot!ers

in order to accomplis! a particular ob;ecti#e.

)ein

Step *

Decision * @es:o

Step 2End

Etc.


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F/*W&'%) SEF/*W&'%) SE

o $ettero $etter understandunderstandand aree on 7hat the "ro#essand aree on 7hat the "ro#ess

is in terms ofis in terms of actions and decision pointsactions and decisionpoints

o determine ho7 the "ro#esso determine ho7 the "ro#ess currently workscurrently works

o determine ho7 the "ro#esso determine ho7 the "ro#ess should workshould work

oo identify wasteidentify wasteand o""ortunities forand o""ortunities for

im"rovementim"rovement


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6OBC7ART SE Continued

To c!ec4 if t!e procedure >as written? flows and

terminates in a loical se9uence( ensurin t!at all steps

are considered and not >left danlin.?

To document procedures

'Common wit! ISO5S +///

To facilitate new employee trainin


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6OBC7ART S@")OS

Depict time consuming stepsin

a process. Examples Inspect a

product( mac!ine a part( record

t!e results( etc.

Acti#ity

or

Tas4

Depict questions/checksand

s!ow alternati#e outcomes

dependin on t!e result.Examples Is t!e part

nonconforminF If yes( do one

t!in. If no( do anot!er.

Decision

:o

6alse

Re;ect

6ail

@es

True

Accept

Pass


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6OBC7ART S@")OS Continued

Depict documents used to

perform tas4s or records

enerated by t!e acti#ity. Examples

Bor4 Instructions 'in

Scrap Record 'out.

Document or Record

'used or enerated

Depict t!e beinnin or end of

a procedure5process.Terminator

')ein or End


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6OBC7ART S@")OS Continued

Depict t!e flow of loic(

decisions( or steps of

documentation.6low

Depict transfer of flow to a

location or s!ow t!e identity of

a location.

A


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Start

Customer Issues Resolution Process (CIRP)

Should issue $e

redire#ted to another

de"artment?

-o

Process Map (Flowchart)February ! "##

)e#ord +ssue

initial issue details

are re#orded in

Fran6lin "lanner

&ustomer +ssue )e"orted

#ustomer issue is re#eived

$y >SE de"artment leader

either via email, voi#e

mail, or $y dire#t #onta#t

+ndentify &oni;ant Enineer

>SE manaement identifies

res"onsi$le #oni;ant

enineer and s#hedules

transmittal meetin

ransmittal 1eetin

>SE manaement

transmits all 6no7n

issue information to

#oni;ant enineer

&larify +ssue

>SE enineer #onta#ts

#ustomer dire#tly to

#larify the issue,

"ro$lem, or #on#ern

+nvestiate @ (erform

)esear#h

revie7 &11As

ather dra7ins

identify relevant sour#es

of information

determine s#o"e of issue

)e"ort +nitial Findin

)e"ort initial findins to

>SE manaement

+s 7or6 #overed

under (rodu#t Su""ort

%reement?

0etermine SE manaement

determines 7hat $udet 7ill$e used to "ay for 7or6

-otify &ustomer

s#o"e of issue is

outside of "rodu#t

su""ort areement

(re"are

4uote?

3es

3es

-o

%uthori;e Wor6

>SE manaement

authori;es 7or6 to $e done

>SE Enineer (erforms Wor6

develo" "lan

develo" s#hedule ma6e #hanes to dra7ins

7rite (%)

et#.

End

-o

Su""ly &ustomer With

Finished (rodu#t

"rovide #ustomer 7ith

finished "rodu#t materials

and data

3es


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EOSCoor$inator

%as& Responsible

Personnel

Determine the $i'isions ha'in the bestan$ worst o'erall results

Form stratey teams

Start "ro#ess

Compare results o three $i'isions orthe pre'ious three years

*naly+e $ata an$ ma&e impro'ementplans

Collect a$$itional $ata

Implement impro'ement Plans an$ inorm$irector

Di'isionManaers

Distribute employeesur'ey results

Director

Discuss results with all $i'ision manaers

Enouh $ata to ma&e impro'ementplans,

Share +nformation

Do urther analysis an$ mo$iyimpro'ement plans

3es

Satisie$ with analysis an$ impro'ementplans,

Stratey%eams

En$ Process

-o

Functional =eploment +ap


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B% ra"hi# tool for des#ri$in ho7 material and

information a#tually move throuh your "ro#ess, and

identifyin the nonvalueadded a#tivities 7ithin the

"ro#ess.

Bsed to streamline and drive #hanes in the "ro#ess$y removin !ueuin, movement, delay and other

a#tivities for 7hi#h a #ustomer is un7illin to "ay.

By"i#ally #reated in t7o "hases: #urrent state and

future state.

-alue Stream Mappin (-SM)

Exam"le from 4uality 0iest 1ar#h CDD, " GExam"le from 4uality 0iest 1ar#h CDD, " G


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Ste" one: 1eetinSte" one: 1eetin

Set u" a meetin $et7een the manaement team andSet u" a meetin $et7een the manaement team and

valuestream "ro#ess o7nersvaluestream "ro#ess o7ners

State the "ur"ose of the VS1 event H to ma" the valueState the "ur"ose of the VS1 event H to ma" the value

stream as it #urrently exists and 7or6s and ain an a##uratestream as it #urrently exists and 7or6s and ain an a##urate

understandin of ho7 the "ro#ess o"erates.understandin of ho7 the "ro#ess o"erates.

sed to !uiet any defensiveness on the "art of "ro#esssed to !uiet any defensiveness on the "art of "ro#ess

o7ners $e#ause the ma" 7ill "ro$e dee"ly into their 7or6o7ners $e#ause the ma" 7ill "ro$e dee"ly into their 7or6

life and ma6e visi$le most of the 7astelife and ma6e visi$le most of the 7aste ..


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Ste" t7o: raininSte" t7o: rainin

rain the VS1 team for t7o "ur"oses.rain the VS1 team for t7o "ur"oses. First, the team needs toFirst, the team needs to understand the #on#e"tsunderstand the #on#e"tsof leadof lead

time, 7aste, valueadded a#tivities and nonvalueaddedtime, 7aste, valueadded a#tivities and nonvalueadded

a#tivities as they "ertain to lean methodoloies.a#tivities as they "ertain to lean methodoloies. Se#ond, the team must 7or6 from a standard set ofSe#ond, the team must 7or6 from a standard set of

definitions and i#ons 7hen dra7in the VS1.definitions and i#ons 7hen dra7in the VS1.

he team then assins t7o to four of its mem$ers tohe team then assins t7o to four of its mem$ers to

#onstru#t the #urrentstate ma".#onstru#t the #urrentstate ma".


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Ste" three: 0ata &olle#tionSte" three: 0ata &olle#tion

(i#6 a "arti#ular "rodu#t of the value stream and follo7 it(i#6 a "arti#ular "rodu#t of the value stream and follo7 it

throuh the "ro#ess if the lead time is less than the num$er ofthrouh the "ro#ess if the lead time is less than the num$er of

days s#heduled for the event. 8usually C days9days s#heduled for the event. 8usually C days9

0ata on ea#h a#tivity 7ithin the value stream should $e0ata on ea#h a#tivity 7ithin the value stream should $e

#olle#ted and #an in#lude:#olle#ted and #an in#lude: &y#le times&y#le times

&haneover or setu" times&haneover or setu" times

-um$er of "eo"le involved-um$er of "eo"le involved

4uantity of units "ro#essed4uantity of units "ro#essed

4uantity of #haneovers for a iven time "eriod4uantity of #haneovers for a iven time "eriod 0o7ntime0o7ntime


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Ste" four: 1a" &onstru#tionSte" four: 1a" &onstru#tion

he #urrentstate ma" #an $e #onstru#ted after ea#hhe #urrentstate ma" #an $e #onstru#ted after ea#h

a#tivity has $een o$served and the data have $eena#tivity has $een o$served and the data have $een

#olle#ted.#olle#ted.

/a$el ea#h a#tivity in a "ro#ess $ox, 7ith the data for that a#tivity/a$el ea#h a#tivity in a "ro#ess $ox, 7ith the data for that a#tivity

listed $elo7 it.listed $elo7 it. se arro7s to sho7 the flo7 of the "rodu#tse arro7s to sho7 the flo7 of the "rodu#t

se trianles $et7een the "ro#ess $oxes to de"i#t inventoryse trianles $et7een the "ro#ess $oxes to de"i#t inventory

levels of 7or6 in "ro#ess $efore ea#h a#tivity.levels of 7or6 in "ro#ess $efore ea#h a#tivity.

0ra7 i#ons and arro7s o""osite the "rodu#t flo7 to sho70ra7 i#ons and arro7s o""osite the "rodu#t flo7 to sho7#ommuni#ation flo7s they sinal u"stream a#tivities that 7ill#ommuni#ation flo7s they sinal u"stream a#tivities that 7ill

rea#t to do7nstream information.rea#t to do7nstream information.


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Ste" four: 1a" &onstru#tion #ont.Ste" four: 1a" &onstru#tion #ont.

he #urrentstate ma" #an $e #onstru#ted.he #urrentstate ma" #an $e #onstru#ted.

0ra7 a sa7 tooth diaram underneath the value stream to de"i#t0ra7 a sa7 tooth diaram underneath the value stream to de"i#t

"ro#ess and lead time. Write the time to "ro#ess a sinle unit of "rodu#t"ro#ess and lead time. Write the time to "ro#ess a sinle unit of "rodu#t

on the diaram2s u""er teeth, and the !ueue time on the lo7er teeth.on the diaram2s u""er teeth, and the !ueue time on the lo7er teeth.

&al#ulate the "ro#ess time for the value stream $y addin the times&al#ulate the "ro#ess time for the value stream $y addin the times

alon the u""er teeth of the sa7 tooth diaram.alon the u""er teeth of the sa7 tooth diaram.

&al#ulate the total lead time $y addin all the times on the u""er teeth&al#ulate the total lead time $y addin all the times on the u""er teeth

and the lo7er a"s toether.and the lo7er a"s toether.

&al#ulate the "er#ent of the total lead time re"resented $y the "ro#ess&al#ulate the "er#ent of the total lead time re"resented $y the "ro#ess

time.time.


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&ustomers $ein

arrivin at I a.m.

for J a.m. o"enin

&ustomers sit

do7n and 7ait for

their num$er to $e

#alled $et7een

ea#h station

&ustomer

)e#eive !ueuin

ti#6et

=&KC minLDD #ustday

C examiners

(ro#essed for

7ritten exam

&K minMD #ustday

G examiner

a6e test on #om

"uter testin station

&KGL to D minGC #om"uters

&om"uteri;ed

testin in Enlish

only

+N to M "eo"le

+L to GD "eo"le

+GDD to CDD "eo"le

/eend

=& K &y#le time

== K +nventory+

==

C min

JD min CD min D min GL min

min CD min

Fiure G: 0river2s /i#ense +ssuan#e:

&urrentState 1a"

%otal processin time . / 1 minutesFiure G: 0river2s /i#ense +ssuan#e:


43/52

&ustomers shuffle

$a#6 and forth

throuh servi#e

#enter: no flo7

%otal processin time . /01 minutes

%otal lea$ time . "2301 minutes

S#ore test and

re#eive "assin

do#umentation

&KC min for

#om"&KL min for

forein lanuae

G examiner

DO failure rate

&om"lete a""li

#ation, sin and

enter in system

&KC.L min

LD #ustday examiners

LO rePe#ted for

la#6 of

do#umentation

&a"ture "hoto and

re#eive money

&KG.L min

LD #ustdayC #ameras

"rinters

C examiners

+GDD to CDD "eo"le

+L to GD

"eo"le

+D to GCD "eo"le

/eend

=& K &y#le time

== K +nventory+

C min

GL min IL min L min

C.L min G.L min

GD min

.L min

(i#6 u" driver2s

li#ense

&K.L min

CL #ustdayC examiners

LO s#ra" rate

+N to L "eo"le

&urrentState 1a"


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Ste" five: )evie7Ste" five: )evie7

*n#e the #urrentstate ma" is #om"leted, #all a meetin*n#e the #urrentstate ma" is #om"leted, #all a meetin

of the manaers and "ro#ess o7ners to revie7 the ma"of the manaers and "ro#ess o7ners to revie7 the ma"

and validate the information.and validate the information.

he data on the ma" are o"en for !uestions, and a #onsensushe data on the ma" are o"en for !uestions, and a #onsensus

must $e rea#hed $efore oin any further.must $e rea#hed $efore oin any further.

%n MD"er#ent a##ura#y level is a##e"ta$le if the team strules%n MD"er#ent a##ura#y level is a##e"ta$le if the team strules

to #ome to a #onsensus on any data $e#ause "rior to #om"letinto #ome to a #onsensus on any data $e#ause "rior to #om"letin

the ma", no level of a##ura#y had existed at all.the ma", no level of a##ura#y had existed at all.


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Ste" six: Set arets for +m"rovementSte" six: Set arets for +m"rovement

se $rainstormin to taret im"rovement initiatives tose $rainstormin to taret im"rovement initiatives to

eliminate and redu#e $ottlene#6s and lead times.eliminate and redu#e $ottlene#6s and lead times.

se an %ffinity 0iaram, +nterrelationshi" 0ira"h, or reese an %ffinity 0iaram, +nterrelationshi" 0ira"h, or ree

0iaram as a""ro"riate.0iaram as a""ro"riate.

%void develo"in im"rovement initiatives that only fo#us on the%void develo"in im"rovement initiatives that only fo#us on the"ro#ess ste"s 7here "rodu#ts are $ein transformed. *ften more"ro#ess ste"s 7here "rodu#ts are $ein transformed. *ften more

than JL "er#ent of the time in a value stream is s"ent "erforminthan JL "er#ent of the time in a value stream is s"ent "erformin

a#tivities that don2t add value. Q)emem$er, the oal of VS1 is toa#tivities that don2t add value. Q)emem$er, the oal of VS1 is to

taret these nonvalueadded a#tivities for 7aste elimination ortaret these nonvalueadded a#tivities for 7aste elimination or

redu#tion.Rredu#tion.R

se an effe#t#ost a""roa#h to "rioriti;e the im"rovementse an effe#t#ost a""roa#h to "rioriti;e the im"rovement

"lan."lan.


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Ste" six: Set arets . &ont.Ste" six: Set arets . &ont.

he team $rainstormed the follo7in im"rovement initiatives:he team $rainstormed the follo7in im"rovement initiatives: % #reative staffin "lan that allo7s for extended hours to eliminate a delue at the% #reative staffin "lan that allo7s for extended hours to eliminate a delue at the

$einnin of the day.$einnin of the day.

Written instru#tions in multi"le lanuaes detailin exa#tly the forms andWritten instru#tions in multi"le lanuaes detailin exa#tly the forms and

do#umentation needed for ea#h servi#e a #ustomer may need.do#umentation needed for ea#h servi#e a #ustomer may need.

)edesin the a""li#ation forms for easier understandin and #reate a des6 7ith)edesin the a""li#ation forms for easier understandin and #reate a des6 7ith

tem"late exam"les 7here #ustomers #an fill out their o7n "a"er7or6.tem"late exam"les 7here #ustomers #an fill out their o7n "a"er7or6.

&reate online "ra#ti#e exams in multi"le lanuaes.&reate online "ra#ti#e exams in multi"le lanuaes. o de#rease the failure rate, #hare for a se#ond test attem"t.o de#rease the failure rate, #hare for a se#ond test attem"t.

% #om"uter$ased testin in multi"le lanuaes, eliminatin "a"er and "en#il testin% #om"uter$ased testin in multi"le lanuaes, eliminatin "a"er and "en#il testin

and manual s#orin.and manual s#orin.

*ne more #amera at the "hoto station to 6ee" u" 7ith demand.*ne more #amera at the "hoto station to 6ee" u" 7ith demand.

% a firstin, firstout line for "hotos and li#ense re#ei"t to "revent #ustomers from% a firstin, firstout line for "hotos and li#ense re#ei"t to "revent #ustomers from

sittin and returnin to the "ro#ess.sittin and returnin to the "ro#ess. )edesin the layout of servi#e #enters to eliminate #onfusion and #reate a #ontinuous)edesin the layout of servi#e #enters to eliminate #onfusion and #reate a #ontinuous

flo7 of #ustomers.flo7 of #ustomers.

&reate a onesto" hel" des6 for #ustomers 7ho have unusual #ir#umstan#es so they&reate a onesto" hel" des6 for #ustomers 7ho have unusual #ir#umstan#es so they

don2t disru"t the flo7.don2t disru"t the flo7.


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Ste" seven: 0ra7 the Futurestate 1a"Ste" seven: 0ra7 the Futurestate 1a"

0ata in the futurestate ma" are derived from tarets that0ata in the futurestate ma" are derived from tarets that

7ill evolve as a result of im"lementin the im"rovements.7ill evolve as a result of im"lementin the im"rovements.

+n most #ases, the futurestate ma" 7ill loo6 similar to the+n most #ases, the futurestate ma" 7ill loo6 similar to the

#urrentstate ma", 7ith the addition of im"roved metri#s.#urrentstate ma", 7ith the addition of im"roved metri#s.

+f a#tivities in the #urrentstate ma" #an $e eliminated or+f a#tivities in the #urrentstate ma" #an $e eliminated or

#om$ined, this should $e refle#ted in fe7er "ro#ess $oxes#om$ined, this should $e refle#ted in fe7er "ro#ess $oxes

in the futurestate ma".in the futurestate ma".

Fiure C: 0river2s /i#ense +ssuan#e:

F t St t 1


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Extend servi#e hours

*"en at I:ND a.m.

)e#eive !ueuin

ti#6et and handout

s"e#ifi# to servi#e

re!uested

&KC min

LDD #ustdayC examiners

Fill out a""ro"riate

a""li#ations and

forms

&K min

Selfservi#e

(ro#essed for 7ritten

exam

&KN min

MD #ustdayG examiner

+G to C "eo"le

+GD to CD

"eo"le

C minGD

min D min min

min N min

D min

CD min

a6e test on #om"uter

testin station

&KGL to D min

GC #om"utersests offered on

#om"uter in many

lanuaes

M

min

)edesin layout for

servi#e #enters to

#reate flo7 from

$einnin to end

&ustomer

+

N to L

"eo"le

FutureState 1a"

%otal processin time . 401 minutesFiure C: 0river2s /i#ense +ssuan#e:

F t St t 1


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0evelo" online"ra#ti#e tests and

#hare for tests after

one failure

%otal processin time 401 minutes

%otal lea$ time . 2/01 minutes

S#ore test and

re#eive "assin

do#umentation

&KC min

G examinerLO failure rate

Sin a""li#ation and

enter in system

&KG.L min

LD #ustday examiners

GO rePe#ted for

la#6 of

do#umentation

&a"ture "hoto and

re#eive money

&KG.L min

CL #ustdayN #ameras

"rinters

N examiners

+GD to GL "eo"le

+N to L

"eo"le

C minM

min min M min

G.L min G.L min

GD min

.L min

a6e test on #om"uter

testin station

&K.L min

CL #ustdayC examiners

LO s#ra" rate

&reate a hel" des6 forany #ustomers 7ith

s"e#ial needs or

"ro$lems that #annot $e

resolved in a timely

fashion

+N to L "eo"le

+GD to GL "eo"le

Fifo /ine

FutureState 1a"


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Ste" seven: 0ra7 the Future #ont.Ste" seven: 0ra7 the Future #ont.

his future state a##om"lished t7o oals of VS1 and leanhis future state a##om"lished t7o oals of VS1 and leante#hni!ues.te#hni!ues.

First, the im"rovement initiative stratey 7as #reated 7ith a sixmonthFirst, the im"rovement initiative stratey 7as #reated 7ith a sixmonth

time frame and the im"rovements that 7ere #alled for 7ere doa$le intime frame and the im"rovements that 7ere #alled for 7ere doa$le in

this time "eriod.this time "eriod.

Se#ond, the team fo#used on im"rovements that 7ere of little or noSe#ond, the team fo#used on im"rovements that 7ere of little or no#ost. his is a 6ey learnin "oint 7ithin lean systems: %void sinifi#ant#ost. his is a 6ey learnin "oint 7ithin lean systems: %void sinifi#ant

investment in #a"ital until the "ro#ess #an2t $e im"roved 7ithout it.investment in #a"ital until the "ro#ess #an2t $e im"roved 7ithout it.

&learly there are many more o"tions to further im"rove the futurestate&learly there are many more o"tions to further im"rove the futurestate

ma".ma".


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Ste" eiht: Formali;e the +m"rovementSte" eiht: Formali;e the +m"rovement

Esta$lish a detailed im"lementation "lan that in#ludes:Esta$lish a detailed im"lementation "lan that in#ludes: he area 7here the im"rovement 7ill o##ur,he area 7here the im"rovement 7ill o##ur,

% des#ri"tion of the im"rovement,% des#ri"tion of the im"rovement,

% !uantifia$le and measura$le oal,% !uantifia$le and measura$le oal,

he "eo"le res"onsi$le for the im"rovementhe "eo"le res"onsi$le for the im"rovement

areted start and #om"letion dates.areted start and #om"letion dates. he se!uen#e of tas6she se!uen#e of tas6s

Set a taret that2s a#hieva$le and measura$le.Set a taret that2s a#hieva$le and measura$le.


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VS1 is a "o7erful tool that #an hel" an orani;ation learn ho7 aVS1 is a "o7erful tool that #an hel" an orani;ation learn ho7 a"ro#ess loo6s from its #ustomers2 "ers"e#tive."ro#ess loo6s from its #ustomers2 "ers"e#tive.

he tool #an $e used to de"i#t the a#tivities 7ithin any $usinesshe tool #an $e used to de"i#t the a#tivities 7ithin any $usiness

"ro#ess, from sho" floor a#tivities to administrative tas6s in the front"ro#ess, from sho" floor a#tivities to administrative tas6s in the front

offi#e.offi#e.

VS1 7ill hel" "eo"le from different de"artments $ride a"sVS1 7ill hel" "eo"le from different de"artments $ride a"s

throuhout the orani;ation and $ein to a""re#iate the im"ortan#e ofthrouhout the orani;ation and $ein to a""re#iate the im"ortan#e of

their roles in the overall "ro#ess.their roles in the overall "ro#ess.

Em"loyees 7ill $ein to thin6 differently a$out the tas6s they "erformEm"loyees 7ill $ein to thin6 differently a$out the tas6s they "erform

and develo" their o7n im"rovement ideas. his is 7hen #ontinuousand develo" their o7n im"rovement ideas. his is 7hen #ontinuous

im"rovement $e#omes a 7ay of life.im"rovement $e#omes a 7ay of life.

VS1 &ommentsVS1 &omments

Process Mapping and Waste.ppt

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Transcript of Process Mapping and Waste.ppt