How to use value stream mapping for continuous improvement. You can also download a free value stream mapping presentation in ppt and pdf. It is schedule to work 2 shift a day 16 hours and a month have 20 days. Any part of the production process that improves the product for the. Changeover time is the measurement of the cycle time from the moment the last good part of the previous process is produced to the moment first good part of the subsequent process is produced. The product family consists of four sizes of scissors, necessitating changeovers at. Time measurement at the pcb assembly line process name printing and solder paste smt reflow oven aoi insertion ict manual cycle time secs 55. Value stream mapping is a lean management tool that helps visualize the steps needed to take from product creation to delivering it to the endcustomer. Often times, sales teams are able to reduce quoted lead times on products and improve customer satisfaction.
In the product flow area of your value stream map include how materials will move from the supplier all the way to a finished good sold to a customer. Percentage of jobs that are complete and accurate the first time that they are processed. The process either needs to be designed to be capable of producing one package every 32 seconds or the changeover time needs to be kaizened. This further complicates the value stream map but can also be ripe for opportunity due to the complexity and number of variables to improve. If youre a novice to using value stream mapping software like lucidchart, youll find that this guide covers all you need to know about the definition, history, and uses of value stream mapping, along with stepbystep instructions for conducting your own value stream analysis.
Sep 25, 2008 the demand does not change so the new takt time is 32. These activities are usually needed to support value adding activities. It is best to start at diagramming a facility level map before attempting to draw a process level map or extended level map so you do not optimize one area and suboptimize another. Data boxes make it possible to write important aspects of each process step, such as changeover times, cycle times and machine availability, which makes value stream mapping a great tool to use in redesigning a value stream panneman, 2017. Value stream mapping can be incredibly useful in various industries. After defining the root problems, the tools like value stream mapping and man machine charts are used to measure the. These activities are usually needed to support valueadding activities.
Correct the map and compare cycle time per item to take time for that activity. You may also create your own symbols for specialized applications. It accounts for where time is spent on this action item. Value stream map and timeline calculations companion. Value stream mapping vsm is a lean manufacturing tool that allows you to see all.
Finally, we sum up the lead time and valuecreating time. Lean principles applied to extended value stream mapping. Calculated as inventory quantity divided by daily customer requirement. Steps to create value stream mapping continuously improving. At the bottom of the map, it is a good idea to add a color code legend if several colors were used for a purpose. Its bread and butter stuff for the lean practitioner.
Create a line chart select the two columns containing the time series data and the quantity of interest columns. Download value stream map sample diagram for visio 2010 from. A value stream map visually displays the flow of steps, delays and information required to deliver a product or service to the customer. Create a line chart select the two columns containing the timeseries data and the quantity of interest columns. In vsm, the ratio of process time value adding time to lead time. Basically, if youre not sure what to use, the line graph will usually do the. An extended value stream map representing what is actually in the status quo. Value stream analysis is an effective way to identify improvement opportunities within a product or service familys value stream, envision a leaner future state and develop an actionable value stream improvement plan to achieve the future state. Value stream mapping is a lean tool that can be used to map processes in detail, based on the both the flow of material as well as information. The non value added time required to convert a line from one product to another. Would the company be hit if changeovers took an hour instead of 2. Below, youll see an example of a value stream map for a software development process.
Reducing changeover time is a key component of implementing a pull production system which operates with as little inventory as possible. Exhibit 1illustrates a conventional value stream map, shows how to denote process inputs and outputs, and provides example of where green supplier network environmental metrics may exist in the product line. Management is considering sharing the sharpen station with another value stream for two. Operating time is 480 minutes, 2 breaks at 10 minutes each, lunch break at 20 minutes, 1 changeover at 30 minutes, total produced 600 parts, zero scrap, cycle time is 30 seconds per part. Nonvalueadding time time spent on activities that do not directly add value to the product. Can someone calculate what the oee percentage would be and show your work. Any part of the production process that improves the product for the customer. Value stream mapping abc stramping company 45 process informationcontinued. The definition of a changeover is the time between the last good part of the current run until the first good part off the next run. Other inputs and outputs that conventional value stream maps identify include changeover and cycle time, labor, and rework. How to create a visualization showing events on time. Reducing changeover time unlocks more productive valueadded time for running production.
Non value adding time time spent on activities that do not directly add value to the product. Smed is a concept aimed at reducing the changeover time, so the eliminated time can be used in the production process. In this table is a sum of the value added time, non value added time, total time, and the value added time expressed as a % of the total time. In companion, when you enter cycle time values in the process task pane, they appear in the troughs of the timeline. Required exam unit 3 and unit 4 due no due date points 100 questions 20 time limit 60 minutes allowed attempts 3 instructions multiple choice exam exam questions are comprised of topics presented in this course. Value stream mapping symbols are not standardized and there are many variations. Typically, you enter cycle time or va ct and nva ct. Blackbelt kindly provide you excel and a3 printable versions to download. It provides key data for each role, including changeover time co, shifts, uptime, and cycle time ct, on a weekly schedule. Waiting defects motion all of the above question 10 5 5 pts all of the following symbols on a value stream map may indicate that you have the waste of inventory except a lightning bolt a triangle with an i in the middle a tombstone a push arrow incorrect question 11 0 5 pts a process is a systematic series of value add activities. A quick changeover is a improvement process using the smed concept for reducing equipment downtime. A time value map can be a very useful tool when utilizing six sigma methodology. Mark the data points with squares, circles, or none at all. File in time network installation instructions 480.
Taking changeover time into account for takt time calculation. Changeover time is the elapsed time between the last good previous product, and the first good next product at the right speed. Include the number of people required to operate the process, touch time and frequency, etc. Setup includes any time that production is stopped last good part locate setup items remove install items trial runs make adjustments first good part traditional view of. Nov 15, 2019 value stream map relates to that broader issue in that it is a tool to assist in that design. Place multiple time series on one graph or place one. Understanding value stream map and related concepts. Hello chacha, reading the process steps, i will measure the cycle time in volume pint, quart, or gallon as well the takt time. Bil is one of the companies engaged in the production of plastic. Value stream mapping allows analysis of the current state map in terms of identifying barriers to flow and waste, calculating total lead time and process time and understanding workinprocess, changeover time. The purpose of a value stream map is to analyze valueadded and nonvalue added activities and delays. Takt time was developed as a manufacturing flow tool in the 1930s.
Value stream map vsm a tool used to improve a process by identifying added value and eliminating waste a process map that follows the value creation process strap yourself to the product or service and see where you go a process map with data added. In traditional lean initiatives, a current state value stream map is drawn. Customer demand and facility data, which you enter on the map task pane, are used to calculate takt time. Most folks are well acquainted with the value stream maps lead time ladder. The elapse time from last part coming out gallon until first next gallon coming out. Reducing changeover time unlocks more productive value added time for running production. The time required to complete a single unit of production co changeover time.
Include every part of your production process with details regarding cycle time, changeover time, uptime, shifts, personnel and available time. One of the most powerful tools in the lean toolbox is the value stream map. Value stream mapping part 1 mapping the current state. Value stream map continuously improving manufacturing. Download scientific diagram updated value stream map with flow and changeover times. Designing a future value stream mapping to reduce lead time. To represent the above and other important elements in a process, there is a somewhat standard or common nomenclature of value stream map symbol. Takt time is calculated from customer demand and facility data. In a short time usually less than an hour you can effectively communicate where the focus of your continuous improvement efforts will have the most impact. Updated value stream map with flow and changeover times. Changeover time time to switch from producing one product on the process to another.
With datetime recognized in excel, it can deal with missing dates nicely. For lead time, we have 50 days for a, 58 days for b, and 43 days for c. Designing a future value stream mapping to reduce lead. It is recommended that you go through all of the content each week before taking the exam. Then, we show a table of all 30 value stream map icons and their definitions. Walk the flow and collect data on the value stream 5. This sample shows how a soda manufacturing company created a highlevel visual map of their value stream, from purchasing to production control to customer service. Total good parts produced divided by total operating time including losses x theoretical partstime unit is your oee. How to create a visualization showing events on time series. Its a tool for reducing waste and improving efficiency, with the goal of providing optimum value to customers in.
The time value map begins with the outset of the work item and it tracks it through delivery to the end user. It is a graphical description of valueadded and nonvalue added time in a process. The demand does not change so the new takt time is 32. Download value stream map sample diagram for visio 2010. Consider an extended level map as the view of the values stream at 60,000 feet, the facility level map at 30,000 feet, and the process level map at 10,000 feet. Value stream map vsm a tool used to improve a process by identifying added value and eliminating waste a process map that follows the value creation process strap yourself to the product or service and see where you go a process map with data added times. The cycle time of a process step is the time from one completed output to the next completed output. Nov 28, 2011 this sample shows how a soda manufacturing company created a highlevel visual map of their value stream, from purchasing to production control to customer service. Lead time indicates total time for a process or series of process. Understand the value stream from the customers point of view and how scheduling tries to meet that need 6. A value stream map visually displays the flow of steps, delays and. An approach that applies best to discrete manual operations and also for.
If you enter all three values, companion will display either cycle time or the sum of va ct and nva ct, whichever value is. Agree action owners and timescales and then implement the action plan. Value stream mapping template value stream map in excel. A time value map tracks a single work item through its process. How to create a time value map brighthub project management. The extended value stream map style highlights steps by type. Form a team to collect data and map the selected value stream 4. Its a tool for reducing waste and improving efficiency, with the goal of providing optimum value to customers in the form of products or services. The nonvalue added time required to convert a line from one product to another ftt first time through. Dec 26, 2017 with date time recognized in excel, it can deal with missing dates nicely.
The value stream map style highlights steps that have value add time. Value stream mapping right in excel easy to use value stream map and vsm symbols. Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Lead time though each process, including time in inventory. We can track any work item into one of the 3 categories. The purpose of takt time is, first and foremost, to serve as a management tool to indicate at a glance whether production is ahead or behind. Creating a value stream map lean manufacturing tools. Operation time total time that is dedicated to a product in a specific operation. If you take a month of data for each equipment and check how many hours equipment was down during the schedule work time. This allows you to view you to view your complete set of processes from a high altitude and very easily see where the. It identifies the process flow as well as the information flow. Customer demand and takt time appear in the upper right corner of the value stream map. The sharpen activity actually has two stations, each with the data shown on the map.
The time taken to set up a process is nonproductive and therefore, non value added from a customers perspective. Value stream mapping symbols a value stream map uses symbols to represent the flow of information and inventory within a system and to streamline those processes. Use it when you have a lot of a points or just a few. Smed helps reduce time in both setup and changeover. Can someone explain the differences between setup time and.
If overall processing time is not equal to value add time, it is shown above the value add time in the timeline. Percentage of jobs that are complete and accurate the first time that they are processed va value added. It also identifies critical metrics such as cycle times, inventory, yield, travel time, changeover time and others. Many lean practitioners see vsm as a fundamental tool to identify waste, reduce process cycle times, and implement process improvement. Qi macros addin for excel makes value stream mapping as easy as 123. The time taken to modify the production line for different products or new batches of the same product 1, 3. Draw a map of the value stream well look at verifying the value stream map in chapter 3.
Setup time is the time to adjust or replace machine parts to accommodate the new product. The changeover time from the last good piece from the previous job pn 4567 to the first good piece this job pn 1298 was 7 minutes. An introduction to value stream mapping and analysis diva. Time value map is a tool that tracks how a specific process spends its time. Value stream mapping vsm is defined as a lean tool that employs a flowchart documenting every step in the process. Include data boxes under each process box, recording data relevant to the purpose of your value stream map. As with other business process mapping methods, it helps with introspection understanding your business better, as well as analysis and process improvement. Sep 06, 2016 in the product flow area of your value stream map include how materials will move from the supplier all the way to a finished good sold to a customer.
Use a value stream map to illustrate the flow of materials and information as a product. If the company works to shift 16 hours a day 57,600 sec. This large gap between valuecreating time and lead time is typical. Value stream map relates to that broader issue in that it is a tool to assist in that design. The amount of actual time between the last good part from the previous production run, and the first good part of the next.
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