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Value-Stream Mapping to Create Value and Eliminate
Muda
Presentedby
Mohammed El BoussamiHafez Shurrab
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Introduction
Value Stream
Mapping
Seven wastes
Supply Chain
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Why Value Stream Mapping Information & materials relation Identify Wastes Continuous Improvement
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Five Steps to do Value Stream Mapping
Product Family
Current State Map
Future State Map
Plan
Value Stream Map
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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 Systems
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ProcessCycleTime(sec.)
Changeover Time(sec.)
Uptime( )
WIP next to the process
(unit), L: lift, R: right (D): Day of Demand
Stamping1 3600 85 4600 L - 2400 R 7.6 D
Welding 39 600 100 1100 L - 600 R 1.8 D
Welding 2 46 600 80 1600 L - 850 R 2.7 DAssembly
62 - 100 1200 L - 640 R 2 D
Assembly 240 - 100 2700 L - 1440 R 4.5 D
The data of Acme's Production Processes
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Current State Map
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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?
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Load-Leveling Box
shift 1 7 720 740 8 820 840 910 930
shift 2 4 420 440 5 520 540 610 630
Left Drive L L L L L
Right Drive R R R
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Future State Map
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Acme Stamping Lead-Time Improvement
Location Coil Stamped Parts Wie/Ass. WIPFinishedGoods
Production LeadTime
Total InventoryTurns
Before 5 Days 7.5 Days 6.5 Days 4.5 Days 23.6 Days 10
Continuous Flow &Pull 2 Days 1.5 Days 0 4.5 Days 8 Days 30
With Leveling 1.5 Days 1 Day 0 2 Days 4.5 Days 53
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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.
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Conclusion (cont.)
Some concerns are:
The diversity of indusries characteristics
Technological limits
Resistance to change
The accessibility of data
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