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A lean manufacturing process first adopted by Toyota
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Transcript
Introduction- What is VSM?
- A lean manufacturing process first adopted by Toyota
- The Value Stream refers to all the actions required to bring the product through the production process
- The mapping refers to drawing a visual representation of every process in both the material and information flows
Benefits of VSM
- Allows the company to see it’s sources of waste
- Gives an overall view of your business process
- Makes it easy to implement changes into your business
- Mapping lets us see the overall production process that needs to be improved rather than each individual process.
- It shows a link between the information flow and the product flow. No other tool does this.
How to Develop a Value Stream Map
- Identifying the product or service family.
- Identify the issue from two different perspectives
- Draw the Current State Value Stream Map
- Identify value added or non-value added activities
- Develop an Ideal State Value Stream Map
- Draw the Future State Value Stream Map
How to Implement a Value Stream Map
- Form a Lean event team and provide Lean training
- Draw a VSM that is easy to analyse and understand
- Walk through the actual steps
- The map should start at the customer end and work back
- Brainstorm to develop Future State Value Stream Map.
- Proposing a Value Stream Plan to implement the FSVSM
- Continuous reviews for improvement
Case Study: Perfecta Centrum Reklamy
Design and manufacture devices which support the products of its customers
Utilised Value Stream Mapping to enhance the process of how customers acquire orders
Old Process :
- 53 steps
- 37 steps classified as ‘waste’
- Only 16 steps value adding
Whole process lasted 74 days
Improvements:
- developing checklists
- amalgamating the sales and project departments
- FIFO rule for queuing projects
- designer and builder training
- developing work standards
Results:
- Lead time- reduced by 70%
- Process time- reduced by 85%
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